Edition 02/2006

A5E00224669-03
Preface

Purpose of the manual

This manual provides all the information required to install, wire, configure and
commission the DP/DP Coupler.

Required basic knowledge

Knowledge required for handling this manual:
• General knowledge in the field of automation engineering
• Knowledge in the use of computers or PC-related equipment (e. g.
programming devices) under the Windows operating system
• Knowledge of STEP 7. Provided in the ”Programming in STEP 7 V5.2” manual.

Area where this manual applies

This manual applies to the DP/DP Coupler, order no. 6ES7 158-0AD01-0XA0.
It describes the components valid at the time of the manual’s publication. We
reserve the right to enclose a product information document containing current
information with new components and new releases of components.

Changes since the previous version

This manual contains the descriptions of enhancements and changes compared
with the previous version:
• Chapter A.1.1 Standards and approvals updated.

DP/DP Coupler
A5E00244669-03 iii
Operating Instructions · Edition 11/2006

Control Unit

CU240S
CU240S DP
CU240S DP-F

Software version 2.1

SINAMICS
G120
s
 Introduction 1

Safety notes 2

Description 3
SINAMICS
Installing/Mounting 4
SINAMICS G120
Control Units CU240S 5
Commissioning (software)

Operation 6
Operating Instructions

Service and maintenance 7

Functions 8

Technical data 9

Spare parts/Accessories 10

Appendix A

List of abbreviations B

Edition 11/2006, Software version V2.1

11/2006
A5E00766042B AA
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. 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
with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.

Caution
without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.

Notice
indicates that an unintended result or situation can occur if the corresponding information is not taken into
account.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.

Qualified Personnel
The device/system may only be set up and used in conjunction with this documentation. Commissioning and
operation of a device/system may only be performed by qualified personnel. Within the context of the safety notes
in this documentation qualified persons are defined as persons who are authorized to commission, ground and
label devices, systems and circuits in accordance with established safety practices and standards.

Prescribed Usage
Note the following:

Warning
This device may only be used for the applications described in the catalog or the technical description and only in
connection with devices or components from other manufacturers which have been approved or recommended by
Siemens. Correct, reliable operation of the product requires proper transport, storage, positioning and assembly
as well as careful operation and maintenance.

Trademarks
All names identified by ® are registered trademarks of the 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.

Siemens AG Order No.: A5E00766042B AA Copyright © Siemens AG 2006.

Automation and Drives Edition 10/2006 Technical data subject to change
Postfach 48 48
90437 NÜRNBERG
GERMANY
Table of contents
1 Introduction............................................................................................................................................. 1-1
1.1 Documents for the SINAMICS G120 ......................................................................................... 1-1
2 Safety notes............................................................................................................................................ 2-1
3 Description.............................................................................................................................................. 3-1
3.1 CU240S...................................................................................................................................... 3-1
3.2 Accessories for the SINAMICS G120 ........................................................................................ 3-2
3.3 Features and functions of the CU240 ........................................................................................ 3-3
3.4 Layout and Block diagram ......................................................................................................... 3-5
3.5 Interfaces of the CU240S variants ........................................................................................... 3-10
3.6 Factory settings of the CU240S control units .......................................................................... 3-16
4 Installing/Mounting.................................................................................................................................. 4-1
4.1 Fitting the CU to the PM............................................................................................................. 4-2
4.2 Connecting the Control Unit via terminals ................................................................................. 4-4
4.2.1 Connecting a CU240S via terminals.......................................................................................... 4-5
4.3 Connecting a CU240S DP or CU240S DP-F via PROFIBUS DP............................................ 4-10
4.3.1 Setting the PROFIBUS DP address via DIP Switches ............................................................ 4-10
4.3.2 Connecting the PROFIBUS DP ............................................................................................... 4-11
4.3.3 Screening the bus cable and EMC precautions....................................................................... 4-15
4.4 Connecting a CU240S via USS ............................................................................................... 4-17
5 Commissioning (software) ...................................................................................................................... 5-1
5.1 General commissioning information .......................................................................................... 5-1
5.2 Parameters................................................................................................................................. 5-2
5.2.1 Write parameters ....................................................................................................................... 5-3
5.2.2 Monitoring parameters ............................................................................................................... 5-3
5.2.3 Parameter Attributes .................................................................................................................. 5-4
5.3 Factory settings........................................................................................................................ 5-10
5.4 Parameterization with Operator Panel..................................................................................... 5-12
5.4.1 Function Keys of the OP .......................................................................................................... 5-13
5.4.2 Changing parameters via OP................................................................................................... 5-14
5.5 Parameterization with MMC..................................................................................................... 5-15
5.6 Parameterization with STARTER............................................................................................. 5-16
5.7 Commissioning modes............................................................................................................. 5-18
5.7.1 Motor data identification........................................................................................................... 5-26
5.7.2 Calculating the motor and control data .................................................................................... 5-29
5.7.3 Commissioning the application ................................................................................................ 5-31
5.7.4 Series Commissioning ............................................................................................................. 5-43

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5.7.4.1 Series commissioning with the OP .......................................................................................... 5-47

5.7.4.2 Series commissioning with STARTER..................................................................................... 5-49
5.7.4.3 Inserting and removing the MMC............................................................................................. 5-50
5.7.4.4 Series commissioning with MMC ............................................................................................. 5-52
5.7.5 Reset parameters to factory settings ....................................................................................... 5-59
5.8 Commissioning the Fail-safe Functions ................................................................................... 5-61
5.8.1 Parameters for fail-safe functions ............................................................................................ 5-64
5.8.2 Password for fail-safe functions ............................................................................................... 5-66
5.8.3 Checksums .............................................................................................................................. 5-66
5.8.4 General steps for commissioning fail-safe functions ............................................................... 5-67
5.8.5 Common step-by-step descriptions for fail-safe functions ....................................................... 5-68
5.8.6 Safety factory reset .................................................................................................................. 5-74
5.8.7 Acceptance Test and Acceptance Log .................................................................................... 5-75
5.9 Commissioning with PROFIBUS DP........................................................................................ 5-77
5.9.1 PROFIdrive Profile ................................................................................................................... 5-77
5.9.2 Using the PROFIBUS DP interface.......................................................................................... 5-77
5.9.3 Data structures within PROFIdrive Profile ............................................................................... 5-82
5.9.4 Standard Telegram structure ................................................................................................... 5-83
5.9.5 VIK/NAMUR Telegram structure .............................................................................................. 5-84
5.9.6 PROFIsafe telegram structure ................................................................................................. 5-85
5.9.7 Switch over behavior of Communication telegram................................................................... 5-86
5.9.8 Control and status words ......................................................................................................... 5-87
5.9.9 Acyclic data transmission......................................................................................................... 5-92
5.9.10 Configuration Example with SIMATIC S7 ................................................................................ 5-99
5.9.10.1 Read Parameters ................................................................................................................... 5-102
5.9.10.2 Write Parameters ................................................................................................................... 5-106
5.10 Encoder Commissioning ........................................................................................................ 5-108
5.10.1 Parameterizing the Encoder Interface ................................................................................... 5-111
5.10.2 Encoder fault codes ............................................................................................................... 5-114
6 Operation................................................................................................................................................ 6-1
6.1 General operation behavior........................................................................................................ 6-1
6.2 Upload and download of parameter sets ................................................................................... 6-2
6.3 Start-up Behavior ....................................................................................................................... 6-6
6.3.1 Normal Start-up behavior of the Inverter.................................................................................... 6-6
6.3.2 Swap Behavior of the Inverter.................................................................................................... 6-8
7 Service and maintenance ....................................................................................................................... 7-1
7.1 Service and support information ................................................................................................ 7-1
7.2 Faults and Alarms ...................................................................................................................... 7-3
7.3 LED Overview ............................................................................................................................ 7-4
7.4 Normal Status LEDs................................................................................................................... 7-6
7.5 Fail-Safe Function Status LEDs................................................................................................. 7-7
7.6 Further indication for LEDs ........................................................................................................ 7-8
7.7 Troubleshooting with the PROFIBUS DP .................................................................................. 7-9
7.8 Troubleshooting with the OP.................................................................................................... 7-13
8 Functions ................................................................................................................................................ 8-1
8.1 BICO Technology....................................................................................................................... 8-1

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8.1.1 Selection of command/setpoint source P0700 and P1000........................................................ 8-1

8.1.2 Using BICO technology.............................................................................................................. 8-3
8.2 Data Sets ................................................................................................................................... 8-6
8.3 Digital inputs (DI) ..................................................................................................................... 8-13
8.4 Digital outputs (DO) ................................................................................................................. 8-16
8.5 Analog inputs (A/D converter).................................................................................................. 8-18
8.6 Analog outputs (D/A converter)................................................................................................ 8-20
8.7 Communication via USS .......................................................................................................... 8-22
8.7.1 Structure of a USS telegram .................................................................................................... 8-24
8.7.2 User data area of USS telegram.............................................................................................. 8-26
8.7.3 Process data channel (PZD).................................................................................................... 8-27
8.7.4 Parameter data channel (PKW) ............................................................................................... 8-28
8.7.5 Timeouts and other errors........................................................................................................ 8-34
8.8 Fixed frequencies..................................................................................................................... 8-37
8.9 2-/3-wire control ....................................................................................................................... 8-41
8.9.1 Siemens standard control (P0727 = 0) .................................................................................... 8-42
8.9.2 2-wire control (P0727 = 1) ....................................................................................................... 8-44
8.9.3 3-wire control (P0727 = 2) ....................................................................................................... 8-45
8.9.4 3-wire control (P0727 = 3) ....................................................................................................... 8-47
8.10 Motorized potentiometer (MOP)............................................................................................... 8-48
8.11 JOG.......................................................................................................................................... 8-50
8.12 PID Controller........................................................................................................................... 8-52
8.12.1 PID motorized potentiometer ................................................................................................... 8-54
8.12.2 PID fixed setpoint..................................................................................................................... 8-54
8.12.3 PID dancer roll control ............................................................................................................. 8-56
8.13 Setpoint channel ...................................................................................................................... 8-59
8.13.1 Summation and modification of frequency setpoint ................................................................. 8-59
8.13.2 Ramp-function generator ......................................................................................................... 8-61
8.13.3 OFF/braking functions.............................................................................................................. 8-63
8.13.4 Manual and automatic operation.............................................................................................. 8-66
8.14 Free function blocks................................................................................................................. 8-69
8.15 Brake functions ........................................................................................................................ 8-74
8.15.1 Electro-mechanical brakes....................................................................................................... 8-74
8.15.1.1 Brake Control Relays ............................................................................................................... 8-75
8.15.1.2 Motor Holding Brake ................................................................................................................ 8-78
8.15.1.3 Instant brake ............................................................................................................................ 8-80
8.15.2 Electronic brakes (only with PM240) ....................................................................................... 8-82
8.15.2.1 DC braking ............................................................................................................................... 8-82
8.15.2.2 Compound braking................................................................................................................... 8-86
8.15.2.3 Dynamic braking ...................................................................................................................... 8-88
8.15.3 Regenerative braking (only with PM250)................................................................................. 8-92
8.16 Automatic restart...................................................................................................................... 8-93
8.17 Flying restart ............................................................................................................................ 8-96
8.18 Fail-safe functions.................................................................................................................... 8-99
8.18.1 Monitoring the fail-safe functions ........................................................................................... 8-101
8.18.2 Limiting values for SS1 and SLS ........................................................................................... 8-103

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8.18.3 Safe Torque Off...................................................................................................................... 8-107

8.18.4 Safe Stop 1 ............................................................................................................................ 8-110
8.18.5 Safely-Limited Speed ............................................................................................................. 8-114
8.18.6 Safe Brake Control................................................................................................................. 8-136
8.19 Closed-loop Vdc control ......................................................................................................... 8-138
8.19.1 Vdc_max controller................................................................................................................. 8-139
8.19.2 Kinetic buffering ..................................................................................................................... 8-141
8.20 Positioning ramp down........................................................................................................... 8-143
8.21 General monitoring functions and messages......................................................................... 8-145
8.21.1 Load torque monitoring .......................................................................................................... 8-147
8.22 Thermal motor protection and overload responses ............................................................... 8-150
8.22.1 Thermal motor model ............................................................................................................. 8-152
8.22.2 Motor Temperature Identification after Restart ...................................................................... 8-153
8.22.3 Temperature sensors ............................................................................................................. 8-154
8.23 Power Module protection ....................................................................................................... 8-157
8.23.1 General overload monitoring.................................................................................................. 8-157
8.23.2 Power module thermal monitoring ......................................................................................... 8-157
8.24 Open-loop and closed-loop control ........................................................................................ 8-160
8.24.1 V/f control ............................................................................................................................... 8-160
8.24.1.1 Voltage boost ......................................................................................................................... 8-163
8.24.1.2 Slip compensation.................................................................................................................. 8-165
8.24.1.3 V/f resonance damping .......................................................................................................... 8-166
8.24.1.4 V/f control with FCC ............................................................................................................... 8-167
8.24.1.5 Current limiting (Imax controller)............................................................................................ 8-168
8.24.2 Vector control ......................................................................................................................... 8-169
8.24.2.1 Vector control without speed encoder.................................................................................... 8-172
8.24.2.2 Vector control with speed encoder......................................................................................... 8-174
8.24.2.3 Speed controller ..................................................................................................................... 8-175
8.24.2.4 Closed-loop torque control ..................................................................................................... 8-180
8.24.2.5 Switch-over from Frequency to Torque Control ..................................................................... 8-182
8.24.2.6 Limiting the torque setpoint .................................................................................................... 8-183
9 Technical data ........................................................................................................................................ 9-1
9.1 CU240S Performance ratings .................................................................................................... 9-1
9.2 Technical data of PROFIBUS DP .............................................................................................. 9-2
10 Spare parts/Accessories ....................................................................................................................... 10-1
10.1 Control Unit accessories .......................................................................................................... 10-1
A Appendix.................................................................................................................................................A-1
A.1 Electromagnetic Compatibility....................................................................................................A-1
A.2 Definition of the EMC Environment and Categories ..................................................................A-2
A.3 EMC Overall Performance .........................................................................................................A-4
A.4 Standards ...................................................................................................................................A-6
A.5 Acceptance Log .........................................................................................................................A-7
A.5.1 Documentation of acceptance test.............................................................................................A-7
A.5.2 Function test of the acceptance test ........................................................................................A-10
A.5.3 Completing the acceptance log................................................................................................A-14

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 Table of contents

B List of abbreviations................................................................................................................................B-1
B.1 Abbreviations ............................................................................................................................. B-1
Index................................................................................................................................................ Index-1

Tables
Table 3-1 Interfaces of the Control Units CU240S..................................................................................... 3-6
Table 3-2 Following interfaces are available, see also figure "Variants of Control Units CU240S"......... 3-10
Table 3-3 Control terminals...................................................................................................................... 3-10
Table 3-4 Settings of the General I/O DIP switches ................................................................................ 3-13
Table 3-5 Example address for the PROFIBUS DP interface.................................................................. 3-14
Table 3-6 Function Selection of Digital Input and Digital Output ............................................................. 3-16
Table 3-7 BICO Command Parameter..................................................................................................... 3-17
Table 3-8 Command Sources for Fixed Frequencies .............................................................................. 3-17
Table 3-9 Faults, Alarms, Monitoring ....................................................................................................... 3-17
Table 4-1 Example address for the PROFIBUS DP interface.................................................................. 4-11
Table 4-2 PIN assignment of the 9-pin sub-D socket .............................................................................. 4-11
Table 4-3 Permissible cable length for one segment............................................................................... 4-12
Table 4-4 Recommended PROFIBUS connectors .................................................................................. 4-13
Table 4-5 9-way SUB-D connector for RS485 ......................................................................................... 4-17
Table 4-6 Recommended PROFIBUS connectors .................................................................................. 4-17
Table 5-1 Parameter attributes - BICO ...................................................................................................... 5-5
Table 5-2 Parameter attributes - access level ........................................................................................... 5-5
Table 5-3 Parameter attributes - Change state.......................................................................................... 5-6
Table 5-4 Parameter attributes - Data types .............................................................................................. 5-6
Table 5-5 Parameter attributes - Unit......................................................................................................... 5-7
Table 5-6 Parameter attributes - Grouping ................................................................................................ 5-8
Table 5-7 Parameter attributes - Active ..................................................................................................... 5-8
Table 5-8 Parameter attributes - Quick commissioning ............................................................................. 5-9
Table 5-9 Parameter attributes - Value range............................................................................................ 5-9
Table 5-10 Data sets .................................................................................................................................... 5-9
Table 5-11 Pre-assignment of the digital inputs for a CU240S *) .............................................................. 5-11
Table 5-12 OP keys and their functions ..................................................................................................... 5-13
Table 5-13 Changing P0003 - parameter access level.............................................................................. 5-14
Table 5-14 Changing P0700 an index parameter - setting OP control ...................................................... 5-14
Table 5-15 Connection possibilities for STARTER .................................................................................... 5-16
Table 5-16 Quick commissioning ............................................................................................................... 5-21

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Table of contents

Table 5-17 Automatic download fault codes .............................................................................................. 5-58

Table 5-18 Parameters for fail-safe functions ............................................................................................ 5-65
Table 5-19 Example address for the PROFIBUS DP interface.................................................................. 5-78
Table 5-20 PROFIBUS DP address ........................................................................................................... 5-78
Table 5-21 PROFIBUS DP parameters...................................................................................................... 5-79
Table 5-22 Parameters for flexible interconnection of process data.......................................................... 5-80
Table 5-23 PROFIBUS DP functions ......................................................................................................... 5-80
Table 5-24 Intput addresses for PROFIsafe signals .................................................................................. 5-85
Table 5-25 Output addresses for PROFIsafe signals ................................................................................ 5-86
Table 5-26 Switch over behavior of telegram structures, Part 1 ................................................................ 5-86
Table 5-27 Switch over behavior of telegram structures, Part 2 ................................................................ 5-86
Table 5-28 Switch over behavior of telegram structures, Part 3 ................................................................ 5-87
Table 5-29 Switch over behavior of telegram structures, Part 4 ................................................................ 5-87
Table 5-30 Switch over behavior of telegram structures, Part 5 ................................................................ 5-87
Table 5-31 Assignment control word 1....................................................................................................... 5-88
Table 5-32 Assignment control word 2 (for VIK/NAMUR not defined) ....................................................... 5-90
Table 5-33 Bit assignments status word 1 (for all PROFIdrive and VIK/NAMUR telegrams) .................... 5-90
Table 5-34 Assignment status word 2 (for VIK/NAMUR not defined) ........................................................ 5-92
Table 5-35 Parameter request ................................................................................................................... 5-94
Table 5-36 Parameter response................................................................................................................. 5-94
Table 5-37 Description of fields in parameter request ............................................................................... 5-95
Table 5-38 Description of fields in parameter response............................................................................. 5-96
Table 5-39 Error values in DPV1 parameter responses ............................................................................ 5-97
Table 5-40 Parameter request ................................................................................................................. 5-102
Table 5-41 Parameter response............................................................................................................... 5-104
Table 5-42 Commissioning the Encoder .................................................................................................. 5-109
Table 5-43 Encoder voltage settings........................................................................................................ 5-110
Table 5-44 Encoder parameters............................................................................................................... 5-111
Table 5-45 Monitoring parameters ........................................................................................................... 5-113
Table 6-1 P8458 settings after a manual parameter download ................................................................. 6-4
Table 6-2 P8458 settings after an automatic parameter download from MMC ......................................... 6-4
Table 6-3 Automatic download fault codes ................................................................................................ 6-8
Table 7-1 Status display............................................................................................................................. 7-6
Table 7-2 Alarm numbers, cause and remedy ......................................................................................... 7-10
Table 7-3 Identification of communications firmware ............................................................................... 7-10
Table 7-4 Standard diagnostics................................................................................................................ 7-11

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 Table of contents

Table 7-5 Parameter accessing error numbers ....................................................................................... 7-12

Table 8-1 Parameter P0700....................................................................................................................... 8-1
Table 8-2 Parameter P1000....................................................................................................................... 8-2
Table 8-3 Binectors .................................................................................................................................... 8-3
Table 8-4 Connectors................................................................................................................................. 8-5
Table 8-5 Possible settings of the digital inputs and analog inputs used as digital inputs ...................... 8-14
Table 8-6 Parameters P0731 to P0733 (frequently used functions/states) ............................................. 8-17
Table 8-7 Pre-set analog outputs............................................................................................................. 8-20
Table 8-8 Max. number of devices and max. cable length ...................................................................... 8-23
Table 8-9 Length of start delay ................................................................................................................ 8-24
Table 8-10 Request identifier (master → inverter) ...................................................................................... 8-29
Table 8-11 Response identifier (inverter → master) ................................................................................... 8-29
Table 8-12 Fault numbers for "Cannot process request" response ........................................................... 8-30
Table 8-13 Regulation for setting the PNU ................................................................................................ 8-31
Table 8-14 Example coding for parameter no. in PKE and IND for P8820, Index 16................................ 8-32
Table 8-15 Character run time ................................................................................................................... 8-34
Table 8-16 Example of direct selection using digital inputs ....................................................................... 8-38
Table 8-17 Example of binary-coding using digital inputs.......................................................................... 8-39
Table 8-18 Redefined digital inputs............................................................................................................ 8-42
Table 8-19 BICO Connections ................................................................................................................... 8-42
Table 8-20 MOP modes of operation ......................................................................................................... 8-49
Table 8-21 Correspondence between the parameters .............................................................................. 8-54
Table 8-22 Example of direct selection using digital inputs ....................................................................... 8-55
Table 8-23 Example of binary-coding using digital inputs.......................................................................... 8-56
Table 8-24 Important parameters for PID dancer roll control..................................................................... 8-58
Table 8-25 BICO parameters for ramp-function generator ........................................................................ 8-63
Table 8-26 Examples of settings of parameter P0810............................................................................... 8-67
Table 8-27 Possible settings for parameters P0700 and P1000................................................................ 8-68
Table 8-28 Free function blocks................................................................................................................. 8-69
Table 8-29 Automatic restart...................................................................................................................... 8-94
Table 8-30 Settings for parameter P1200 .................................................................................................. 8-96
Table 8-31 Extract of monitoring functions and messages ...................................................................... 8-146
Table 8-32 Extract from IEC85 thermal classes ...................................................................................... 8-152
Table 8-33 V/f characteristics (parameter P1300) ................................................................................... 8-162
Table 8-34 Voltage boost ......................................................................................................................... 8-164
Table 8-35 Vector control versions .......................................................................................................... 8-171

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Table 8-36 Closed-loop torque control ..................................................................................................... 8-182

Table 9-1 CU240 Performance ratings....................................................................................................... 9-1
Table A-1 Compliance Table ......................................................................................................................A-3
Table A-2 Conducted & Radiated Emissions .............................................................................................A-4
Table A-3 Harmonic Currents .....................................................................................................................A-4
Table A-4 EMC Immunity............................................................................................................................A-5
Table A-5 Machine description and overview/block diagram .....................................................................A-7
Table A-6 Fail-safe functions for each drive ...............................................................................................A-8
Table A-7 Description of the fail-safe equipment/devices ..........................................................................A-9
Table A-8 "Safe Torque Off" function (STO).............................................................................................A-11
Table A-9 "Safe Stop 1" function (SS1) ....................................................................................................A-12
Table A-10 "Safely-Limited Speed" function (SLS) ....................................................................................A-13
Table B-1 Abbreviations used with the SINAMICS G120 Products ...........................................................B-1

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x Operating Instructions, 11/2006, A5E00766042B AA
Introduction 1
1.1 Documents for the SINAMICS G120

Available documentation
The following document types are available for the SINAMICS G120 inverters:
● Brochure
● Catalog
● Getting started Guide
● Operating Instructions
● Hardware Installation Manual
● Compact Operating Instructions (for the Control Units)
● Parameter List.
The documents can be downloaded from the Internet via the following link:
http://www.siemens.de/sinamics-g120
Furthermore you will find in the internet:
● Detailed technical information under:
http://support.automation.siemens.com/WW/view/de/22339653/133000
● Application examples under:
http://support.automation.siemens.com/WW/view/de/20208582/136000

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 1-1
Introduction
1.1 Documents for the SINAMICS G120

Description of the documents

Brochure
The brochure is advertising literature designed to introduce the product to the marketplace. It
contains a basic outline of the product with a brief overview of the technical capabilities of
the product.

Catalog
The catalog presents information that allows the customer to select an appropriate inverter
including all available options. It contains detailed technical specifications, ordering and
pricing information to allow the customer to order the appropriate items for their application
or plant.

Getting started Guide

The Getting started Guide presents warnings, dimension drawings and a brief set up
information for the customer.

Operating Instructions
The Operating Instructions gives information for the Control Unit regarding the features of
the product. It gives detailed information on commissioning, control modes, system
parameters, troubleshooting, technical specifications and the available options from the
product.

Hardware Installation Manual

The Hardware Installation Manual gives information for the Power Modules regarding the
features of the product. It gives detailed information on installation, technical specifications,
dimension drawings and the available options from the product.

Compact Operating Instructions

The Compact Operating Instructions gives a brief description of the installation,
commissioning and control modes as well as an overview of troubleshooting, technical
specifications and the available options from the product.

Parameter List
The Parameter List contains a detailed description of all the parameters that can be modified
and adapted for specific applications. The Parameter List also contains a series of function
diagrams to diagramatically portray the nature and interoperability of the system parameters.

Control Units CU240S

1-2 Operating Instructions, 11/2006, A5E00766042B AA
Safety notes 2
Safety Instructions
The following Warnings, Cautions and Notes are provided for your safety and as a means of
preventing damage to the product or components in the connected machines. This section
lists Warnings, Cautions and Notes, which apply generally when handling the SINAMICS
G120 product, classified as General, Transport and Storage, Commissioning, Operation,
Repair and Dismantling and Disposal.
Specific Warnings, Cautions and Notes that apply to particular activities are listed at the
beginning of the relevant sections in this manual and are repeated or supplemented at
critical points throughout these sections.
Please read the information carefully, since it is provided for your personal safety and will
also help prolong the service life of your SINAMICS G120 product and the equipment to
which it is connected.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 2-1
Safety notes

General

Warning
This equipment contains dangerous voltages and controls potentially dangerous rotating
mechanical parts. Non-compliance with the Warnings or failure to follow the instructions
contained in this manual can result in loss of life, severe personal injury or serious damage
to property.
Only suitable qualified personnel should work on this equipment, and only after becoming
familiar with all safety notices, installation, operation and maintenance procedures contained
in this manual. The successful and safe operation of this equipment is dependent upon its
proper handling, installation, operation and maintenance.
Take particular notice of the general and regional installation and safety regulations
regarding work on dangerous voltage installation (e.g. EN 50178) as well as the relevant
regulations regarding the correct use of tools and personal protective equipment (PPE).

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 operating instructions within easy reach of the equipment and make them
available to all users.
Whenever measuring or testing has to be performed on live equipment, the regulations of
Safety Code BGV A2 must be observed, in particular § 8 "Permissible Deviations when
Working on Live Parts". Suitable electronic tools should be used.
Before installing and commissioning, please read these safety instructions and warnings
carefully and all the warning labels attached to the equipment. Make sure that the warning
labels are kept in a legible condition and replace missing or damaged labels.

Control Units CU240S

2-2 Operating Instructions, 11/2006, A5E00766042B AA
 Safety notes

Transport and storage

Warning
Correct transport, storage as well as careful operation and maintenance are essential for the
proper and safe operation of the equipment.

Caution
Protect the equipment against physical shocks and vibration during transport and storage. It
is important that the equipment is protected from water (rainfall) and excessive
temperatures.

Commissioning

Warning
Working on the equipment by unqualified personnel or failure to comply with warnings can
result in severe personal injury or serious damage to material. Only suitably qualified
personnel trained in the setup, installation, commissioning and operation of the product
should carry out work on the equipment.

Caution
Cable connection
The control cables must be laid separately from the power cables. Carry out the connections
as shown in the installation section in this manual, to prevent inductive and capacitive
interference from affecting the correct function of the system.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 2-3
Safety notes

Operation

Warning
The SINAMICS G120 inverters operate at high voltages.
When operating electrical devices, it is impossible to avoid applying hazardous voltages to
certain parts of the equipment.
Emergency Stop facilities according to EN 60204, IEC 204 (VDE 0113) must remain
operative in all operating modes of the control equipment. Any disengagement of the
Emergency Stop facility must not lead to an uncontrolled or an undefined restart of the
equipment.
Certain parameter settings may cause the SINAMICS G120 inverter to restart automatically
after an input power failure, for example, the automatic restart function.
Wherever faults occurring in the control equipment can lead to substantial material damage
or even grievous bodily injury (that is, potentially dangerous faults), additional external
precautions must be taken or facilities provided to ensure or enforce safe operation, even
when a fault occurs (e.g. independent limit switches, mechanical interlocks, etc.).
Motor parameters must be accurately configured for motor overload protection to operate
correctly.
This equipment is capable of providing internal motor overload protection according to
UL508C. Refer to P0610 and P0335, i²t is ON by default.
Only Control Units with fail-safe functions can be used as an "Emergency Stop Mechanism"
(see EN 60204, section 9.2.5.4).

Repair

Warning
Repairs on equipment may only be carried out by Siemens Service, by repair centers
authorized by Siemens or by authorized personnel who are thoroughly acquainted with all
the warnings and operating procedures contained in this manual.
Any defective parts or components must be replaced using parts contained in the relevant
spare parts list.
Disconnect the power supply before opening the equipment for access.

Control Units CU240S

2-4 Operating Instructions, 11/2006, A5E00766042B AA
 Safety notes

Dismantling and disposal

Caution
The packaging of the inverter is re-usable. Retain the packaging for future use.
Easy-to-release screw and snap connectors allow you to break the unit down into its
component parts. You can recycle these component parts, dispose of them in accordance
with local requirements or return them to the manufacturer.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 2-5
Description 3
The SINAMICS G120 range
The SINAMICS G120 inverter has been designed for the accurate and efficient control of the
speed and torque for three-phase motors. The SINAMICS G120 system comprises two basic
modules, the Control Unit (CU) and the Power Module (PM).
The Control Units are divided into the following:
● Standard CUs (CUs without fail-safe functions)
– CU240S
– CU240S DP like CU 240S plus PROFIBUS DP interface
● CUs with fail-safe functions
– CU240S DP-F like CU240S DP plus integrated fail-safe functions
The Power Modules are divided as follows:
● PM240 Power module with dc braking functions, supply voltage 3 AC 400 V
● PM250 Power module with regenerative mode supply voltage
– 3 AC 400 V
– 3 AC 690 V
Control Units and Power modules are allowed to be combined in any possible configuration.
See the respective manual for specific functions and features.

3.1 CU240S

This manual …
… decribes functions and features of the control units
● CU240S
● CU240S-DP
● CU240S DP-F

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 3-1
Description
3.2 Accessories for the SINAMICS G120

3.2 Accessories for the SINAMICS G120

Overview
The following options are available for the SINAMICS G120 Inverters:

Control Unit accessories

● OP (Operator Panel)
● PC connection kit
● MMC (Multi Media Card)
● CU Screen termination kit

Power Module PM240 accessories

● DIN rail mounting kit
● NEMA 1 kit
● Screen termination kit
● Brake relay and safe brake relay
● Output reactors
● Line reactors
● Line filters
● Braking resistor.

Power Module PM250, 400 V accessories

● DIN rail mounting kit
● NEMA 1 kit
● Screen termination kit
● Brake relay and safe brake relay
● Output reactors

Power Module PM250, 690 V accessories

● Screen termination kit
● Brake relay and safe brake relay.

Power Module spare parts

● Fan.

Control Units CU240S

3-2 Operating Instructions, 11/2006, A5E00766042B AA
 Description
3.3 Features and functions of the CU240

3.3 Features and functions of the CU240

Common features
● Modular inverter
● Simple to install
● Signals can be interconnected using BICO technology
● Different data sets selectable
● Fast current limiting (FCL) for trip-free operation
● Easy exchange of power module or control unit (swap or hot swap)
● Rugged EMC design
● Configurable for a wide range of applications
● Non-volatile saving of parameter settings - either in the EEPROM of the CU or on an
MMC
● Status display via LEDs on the control unit
● High pulse frequencies for low noise motor operation
● EM brake relay.

Features in combination with a PM240

● Built-in braking chopper for dynamic braking
● DC-link voltage controller
● Kinetic buffering

Features in combination with a PM250

● Regenerative capability

Commissioning functions
● Quick commissioning
● Motor/control data calculation
● Motor data identification
● Application commissioning
● Series commissioning
● Parameter reset to the factory setting.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 3-3
Description
3.3 Features and functions of the CU240

Operating functions
● Adjustable setpoint channel
● Adjustable ramp-function generator (RFG)
● JOG mode
● Freely-assignable function blocks (FFB)
● Positioning ramp down
● Automatic restart (WEA)
● Flying restart
● Current limiting
● Slip compensation
● Motor holding brake (MHB).

Control functions
● V/f control with different characteristics
● SLVC (Sensorless vector control mode) speed and torque
● VC (Vector control mode with encoder) speed and torque

Protective functions
● Motor protective functions
● Inverter protective functions
● Plant/system protective functions.

Fail-Safe Functions (only for CU240S DP-F)

● Safe Torque Off (STO)
● Safe Stop 1 (SS1)
● Safely-Limited Speed (SLS)
● Safe Brake Control (SBC).
The fail-safe functions can be triggered via Digital inputs (FDI0A … FDI1B) or PROFIsafe.

Control Units CU240S

3-4 Operating Instructions, 11/2006, A5E00766042B AA
 Description
3.4 Layout and Block diagram

3.4 Layout and Block diagram

Layout characteristics of the CU240S variants

The figure below shows the various interfaces and control that are available on the Control
Unit.

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Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 3-5
Description
3.4 Layout and Block diagram

Variants

Table 3-1 Interfaces of the Control Units CU240S

Control Unit CU240S CU240S DP CU240S DP-F

Digital Inputs 9 9 6
Fail-safe digital Inputs -- -- 2
Digital Outputs 3 3 3
Analog Inputs 2 2 2
Analog Outputs 2 2 2
PTC/KTY84 interface 1 1 1
MMC interface 1 1 1
Encoder interface 1, TTL or HTL 1, TTL or HTL 1, TTL or HTL
Option port Starter or Starter or Starter or
OP interface OP interface OP interface
Bus interface USS on RS485 PROFIBUS PROFIBUS,
PROFIsafe
Ext. 24 V Yes Yes Yes

Control Units CU240S

3-6 Operating Instructions, 11/2006, A5E00766042B AA
 Description
3.4 Layout and Block diagram

CU240S Block Diagram

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Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 3-7
Description
3.4 Layout and Block diagram

CU240S DP Block Diagram

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Control Units CU240S

3-8 Operating Instructions, 11/2006, A5E00766042B AA
 Description
3.4 Layout and Block diagram

CU240S DP-F Block Diagram

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Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 3-9
Description
3.5 Interfaces of the CU240S variants

3.5 Interfaces of the CU240S variants

Overview

Table 3-2 Following interfaces are available, see also figure "Variants of Control Units CU240S"

CU240S CU240S DP CU240S DP-F

MMC slot x x x
Option port x x x
Terminals x x x
General I/O DIP switches x x x
PROFIBUS DP DIP switches -- x x
Status LEDs x x x
Power module interface (PM-IF) x x x
SUB-D connector (RS485 or PROFIBUS) x x x

MMC
The Multi Media Card (MMC) is a small, removable flash storage device, with a low power
consumption which provides the ability to store data sets for the inverter.
The MMC provides non volatile data storage which requires no power to maintain the data
stored on the card.
It is recommended that the SINAMICS-MMC (order number: 6SL3254-0AM00-0AA0) is used
for the storage and transfer of data sets.

Option port
Via the Option port the OP is connected to the inverter, it can also be used to connect a PC
via the PC Connection Kit to the inverter for parameterizing using STARTER.

Terminals

Table 3-3 Control terminals

Terminal Designation Function CU240S/ CU240S DP-F

CU240S DP
1 +10V OUT Non-isolated output +10 V, max. 10 mA x x
2 0V OUT Supply reference (terminal 1) x x
3 AI0+ Analog input 0 positive x x
4 AI0- Analog input 0 negative x x
5 DI0 Digital input 0, isolated x x
6 DI1 Digital input 1, isolated x x
7 DI2 Digital input 2, isolated x x
8 DI3 Digital input 3, isolated x x

Control Units CU240S

3-10 Operating Instructions, 11/2006, A5E00766042B AA
 Description
3.5 Interfaces of the CU240S variants

Terminal Designation Function CU240S/ CU240S DP-F

CU240S DP
9 U24V OUT Isolated output +24 V – max. 100 mA x x
10 AI1+ Analog input 1 positive x x
11 AI1- Analog input 1 negative x x
12 AO0+ Analog output 0 positive x x
(0/4 mA … 20 mA, 0/2 V … 10 V with 500 Ω
load)
13 AO0- Analog output 0 negative x x
14 PTC+ Motor temperature sensor (PTC or KTY84-130) x x
15 PTC- Motor temperature sensor (PTC or KTY84-130) x x
16 DI4 Digital input 4, isolated x x
17 DI5 Digital input 5, isolated x x
18 DO0, NC Digital output relay 0. normally closed, x x
0.5 A, 30 V DC
19 DO0, NO Digital output relay 0. normally open, 0.5 A, 30 V x x
DC
20 DO0, COM Digital output relay 0. common, x x
0.5 A, 30 V DC
21 DO1, NO Digital output relay 1. normally open, x x
0.5 A, 30 V DC
22 DO1, COM Digital output relay 1. common, x x
0.5 A, 30 V DC
23 DO2, NC Digital output relay 2. normally closed, x x
0.5 A, 30 V DC
24 DO2, NO Digital output relay 2. normally open, x x
0.5 A, 30 V DC
25 DO2, COM Digital output relay 2. common, x x
0.5 A, 30 V DC
26 AO1+ Analog output 1 positive x x
(0/4 mA … 20 mA, 0/2 V … 10 V with 500 Ω
load)
27 AO1- Analog output 1 negative x x
28 U0V OUT Supply reference (terminal 9) x x
31 +24V IN 24 V input supply x x
32 0V IN Supply reference (terminal 31) x x
33 ENC+ SUPPLY 5 V or 24 V power supply for Encoder configured x x
by DIP switch, max. 300 mA
40 DI6 Digital input 7, isolated x --
41 DI7 Digital input 8, isolated x --
42 DI8 Digital input 9, isolated x --
60 FDI0A Fail-safe Digital Input 0A -- x
61 FDI0B Fail-safe Digital Input 0B -- x
63 FDI1A Fail-safe Digital Input 1A -- x
64 FDI1B Fail-safe Digital Input 1B -- x
70 ENC AP Channel A non-inverting input x x
71 ENC AN Channel A inverting input x x

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 3-11
Description
3.5 Interfaces of the CU240S variants

Terminal Designation Function CU240S/ CU240S DP-F

CU240S DP
72 ENC BP Channel B non-inverting input x x
73 ENC BN Channel B inverting input x x
74 ENC ZP Channel 0 (zero) non-inverting input x x
75 ENC ZN Channel 0 (zero) inverting input x x
The control terminals have a maximum tighten torque of 0.25 Nm (2.2 lbf.in) and a nominal
cross section of 1.5 mm2 (AWG 14) for cable.

Terminal layout of the CU240S variants

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Control Units CU240S

3-12 Operating Instructions, 11/2006, A5E00766042B AA
 Description
3.5 Interfaces of the CU240S variants

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General I/O DIP switches (CU240S, CU240S DP and CU240S DP-F)

There are seven general I/O DIP switches that allow the settings described below.
In the factory setting the I/O DIP switches are in the OFF position.

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Table 3-4 Settings of the General I/O DIP switches

DIP switch 1 2 3 4 5 6 7
Meaning AI0 AI1 24 V Encoder 5 V Encoder Encoder A Encoder B Encoder Z
supply supply termination termination termination
ON 0 mA ... 0 mA ... 24 V 5V Encoder A Encoder B Encoder Z
20 mA 20 mA ON ON ON

OFF -10 V ... 0 V ... 10 V 0V 0V Encoder A Encoder B Encoder Z

+10 V OFF OFF OFF

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 3-13
Description
3.5 Interfaces of the CU240S variants

PROFIBUS DP DIP switches (CU240S DP and CU240S DP-F)

The PROFIBUS DP address can be set via seven DIPswitches or via parameter "P0918". If
an address is set via DIP switches, the value of p0918 will be ignored. The PROFIBUS DP
address can be set between 1 and 125.
In the factory setting the PROFIBUS DP address DIP switches are in the OFF position.

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Figure 3-8 PROFIBUS address DIP switches

Table 3-5 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

Status display via LEDs

The SINAMICS G120 inverters provide multiple functions and operating states which are
indicated via LEDs.
LEDs for standard CUs
The status for standard inverters is displayed via the following LEDs:

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Figure 3-9 Status LEDs for standard inverters

Control Units CU240S

3-14 Operating Instructions, 11/2006, A5E00766042B AA
 Description
3.5 Interfaces of the CU240S variants

LEDs for CUs with fail-safe functions

For inverters with fail-safe functions the following additional LEDs are available:

(QG 6DIH
6WDWH 6WRS

6DIH 6DIHO\
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2II 6SHHG

Figure 3-10 LEDs for CUs with fail-safe functions

For detailed description refer to "LED overview" in section "Service and maintenance".

Power module interface

All necessary control signals for the correct operation of the inverter-system are transferred
between the CU and PM utilizing the Power module interface (PM-IF).

SUB-D connector
Via the SUB-D connector - depending on the type of Control Unit - the following interfaces
are available:

• USS on RS485 CU240S For connecting e.g. USS master or STARTER

• PROFIBUS DP CU240S DP For connecting e.g. SIMATIC S7 and STARTER as
class 2 master
• PROFIBUS DP CU240S For connecting e.g. SIMATIC S7 and STARTER as
DP-F class 2 master

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 3-15
Description
3.6 Factory settings of the CU240S control units

3.6 Factory settings of the CU240S control units

Factory Settings for command and setpoint source

P0700 = 0 is the same as P0700 = 2 or 6 dependend on type of Control Unit.

Note
Setting P0700 = 6 (command source via fieldbus communication) and P1000 = 6 (setpoint
source via fieldbus communication) are not possible with a CU240S
Setting P0700 = 5 (command source via USS communication) and P1000 = 5 (setpoint
source via USS communication) are not possible with a CU240S DP or a CU240S DP-F

Table 3-6 Function Selection of Digital Input and Digital Output

Parameter CU240S CU240S DP, CU240S DP-F

P0700 = 2 P0700 = 6
P0701 1 0 0
P0702 12 0 0
P0703 9 9 9
P0704 15 15 15
P0705 16 16 16
P0706 17 17 17
P0707 18 18 ---
P0708 0 0 ---
P0709 0 0 ---
P0731 52.3 52.3 52.3
P0732 52.7 52.7 52.7
P0733 0.0 0.0 0.0

Control Units CU240S

3-16 Operating Instructions, 11/2006, A5E00766042B AA
 Description
3.6 Factory settings of the CU240S control units

Table 3-7 BICO Command Parameter

Parameter CU240S CU240S DP, CU240S DP-F

P0700 = 2 P0700 = 6
P0840 722.0 2090.0
P0842 0.0 0.0
P0844 1.0 2090.1
P0845 19.1 19.1
P0848 1.0 2090.2
P0849 1.0 1.0
P0852 1.0 2090.3

Table 3-8 Command Sources for Fixed Frequencies

Parameter CU240S CU240S DP, CU240S DP-F

P0700 = 2 P0700 = 6
P1020 722.3 722.3
P1021 722.4 722.4
P1022 722.5 722.5
P1023 722.6 722.6 (0.0 for CU240S DP-F)

Table 3-9 Faults, Alarms, Monitoring

Parameter CU240S CU240S DP, CU240S DP-F

P0700 = 2 P0700 = 6
P2103 722.2 722.2
P2104 0.0 2090.7
P2106 1.0 1.0

Factory Settings for Setpoint Source

Source CU240S CU240S DP, CU240S DP-F

P1000 = 2 P1000 = 6
Frequency setpoint Analog setpoint (P0754 [%]) Fieldbus (P2050.1 [Hex])

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 3-17
Installing/Mounting 4
Installing the Control Unit
The CU controls the functions of the PM. The CU cannot be used without a PM, also the PM
cannot be used without a CU.

Warning
An inverter can be switched on unintentionally if the installation is not performed correctly.
The inverter must be started-up by personnel who are qualified and trained in installing
systems of this type.





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Figure 4-1 General layout of a CU240 Control Unit

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 4-1
Installing/Mounting
4.1 Fitting the CU to the PM

4.1 Fitting the CU to the PM

Fitting the Control Unit to the Power Module

The Control Unit is snapped on to 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.





Figure 4-2 Fitting the control unit to the power module

24 V power supply
Normally the CU is supplied with 24 V from Power Module. But it is also possible to use an
external DC 24 V supply (20.4 V … 28.8 V, 0.5 A). It must be connected to the Control Unit
terminals 31 (+ 24 V In) and 32 (0 V In). Some reasons for using an external 24 V power
supply are:
● The PROFIBUS DP interface is required to communicate with the Control Unit when the
Power Module mains power is not present
● Supply for 24 V encoder

Control Units CU240S

4-2 Operating Instructions, 11/2006, A5E00766042B AA
 Installing/Mounting
4.1 Fitting the CU to the PM

Caution
Care must be taken to ensure that the 24 V DC power is connected correctly or damage
to the Control Unit may occur.
Max. cable length on 24 V DC supply and I/O cables connected to CU must not exceed
10 m. Use of unscreened cables is possible however we recommend to use screened
cables.

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.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 4-3
Installing/Mounting
4.2 Connecting the Control Unit via terminals

4.2 Connecting the Control Unit via terminals

General
To have access to the control terminals, the terminal cover must be removed, as shown in
the figure below. The control terminals have a maximum tighting torque of 0.25 Nm
(2.2 lbf.in) and a nominal cable cross section of 1.5 mm2.

Figure 4-3 Removing the Control Unit terminal cover

The terminals of the CU240 control units are combined to terminal blocks. They can be
detached from the control unit, as shown in the figure below.This allows the control units to
be swapped out for another of the same type without the need for rewiring.

Figure 4-4 Removing the two-part connectors with a CU240S DP as example

After all the wiring of the control unit is completed - ensure that the terminal cover is
replaced.

Control Units CU240S

4-4 Operating Instructions, 11/2006, A5E00766042B AA
 Installing/Mounting
4.2 Connecting the Control Unit via terminals

4.2.1 Connecting a CU240S via terminals

Terminal wiring examples for the Control Unit CU240S

Note
To control the CU240S DP or CU240S DP-F via terminals is also possible, but in this case
the parameter settings for command and setpoint source have to be changed.

In this section examples of controlling a SINAMICS G120 inverter with a CU240S via
terminals are shown.
● Basic control with the default settings
● Frequency setpoint and an additional setpoint via terminals
(AI0 and AI1 used as voltage inputs)
● Frequency setpoint and an additional setpoint via terminals
(AI0 and AI1 used as current inputs).

Basic control with the default settings

When shipped from the factory the G120 inverter (control unit and power module) must not
be operated before the values depending on the specific PM are read into the CU.
This can be done via:
● downloading a valid parameter set from an MMC or an OP
● quick commissioning
● a factory reset
To operate the inverter with the basic settings (e.g. after factory reset, without additional
parameterization or DIP switch setting), the following conditions have to be fullfilled:
● The rated current of the inverter is at least as great as the rated current of the motor.
● The power range of the inverter matches the power range of the motor.
● The controlled motor is a 4-pole motor (best Siemens 1LA7).
● The rated motor frequency is 50 Hz, power dimension unit is kW.

Control settings
Digital and analog inputs for commands and setpoints are parameterized for a cabling as
shown in the following figure. Furthermore the state of the inverter is monitored via digital
and analog outputs.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 4-5
Installing/Mounting
4.2 Connecting the Control Unit via terminals

'2 '2 '2 '2 '2 '2 '2 '2 (1& (1& (1& (1& (1& (1&
1& 12 &20 12 &20 1& 12 &20 $3 $1 %3 %1 =3 =1
             

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Figure 4-5 Default control wiring of a CU240S

Frequency setpoint and an additional setpoint via terminals

AI0 and AI1 used as voltage inputs
This type of control wiring allows a main frequency setpoint and an additional setpoint to be
established, using potentiometers on analog inputs AI0 and AI1.
The figure below shows the wiring that is necessary to accomplish this functionality.

Control Units CU240S

4-6 Operating Instructions, 11/2006, A5E00766042B AA
 Installing/Mounting
4.2 Connecting the Control Unit via terminals

DIP switch Settings

The general I/O DIP switches 1 and 2 are used to configure the analog inputs (AI). For using
AI0 and AI1 as voltage inputs set DIP switches 1 and 2 to OFF position.For detailed
information refer to "Analog input" in section "Function".
Parameter Settings
No additional parameters require to be modified.

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1& 12 &20 12 &20 1& 12 &20 $3 $1 %3 %1 =3 =1
             

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Figure 4-6 Terminal connection for using AI0 and AI1 as voltage inputs for main and
additionalsetpoint

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 4-7
Installing/Mounting
4.2 Connecting the Control Unit via terminals

Frequency setpoint and an additional setpoint via terminals

AI0 and AI1 used as current inputs
This type of control wiring allows a main frequency setpoint and an additional setpoint to be
established, for example from a PLC.
The figure below shows the wiring that is necessary to accomplish this functionality.
DIP switch Settings
The general I/O DIP switches 1 and 2 are used to configure the analog inputs (AI). For using
AI0 and AI1 as voltage inputs set DIP switches 1 and 2 to OFF position. For detailed
information refer to "Analog input" in section "Function".
Parameter Settings
The following parameter need to be changed to the values given below. These changes
must only be made after the Quick Commissioning procedure has been completed.
To use 0 mA … 20 mA
● P0003 = 3 Sets the access level to Expert.
● P1000[0] = 22 Setpoint now expected from the analog inputs.
● P0756[0] = 2 Sets analog input 0 (AI0) to current input.
● P0756[1] = 2 Sets analog input 1 (AI1) to current input.
To use 4 mA … 20 mA
The following additional parameters need to be modified:
● P0757[0] = 4 Sets analog input 0 (AI0) to a minimum of 4 mA.
● P0761[0] = 4 Sets the deadband width of analog input 0 (AI0).
● P0757[1] = 4 Sets analog input 1 (AI1) to a minimum of 4 mA.
● P0761[1] = 4 Sets the deadband width of analog input 1 (AI1).

Note
Index [0] is analog input 0, Index [1] is analog input 1, if you are only using one analog
input then you only need to change those indices for the specific analog input.

Control Units CU240S

4-8 Operating Instructions, 11/2006, A5E00766042B AA
 Installing/Mounting
4.2 Connecting the Control Unit via terminals

'2 '2 '2 '2 '2 '2 '2 '2 (1& (1& (1& (1& (1& (1&
1& 12 &20 12 &20 1& 12 &20 $3 $1 %3 %1 =3 =1
             

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', ', ', ', ', ', ', ', ',
6833/<
           

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9 9
        ,1 ,1  
             

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RU RU
P$ P$

Figure 4-7 Terminal connection for using AI0 and AI1 as current inputs for main and additional
setpoint

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 4-9
Installing/Mounting
4.3 Connecting a CU240S DP or CU240S DP-F via PROFIBUS DP

4.3 Connecting a CU240S DP or CU240S DP-F via PROFIBUS DP

PROFIBUS DP Interface
The function of the PROFIBUS DP interface is to provide a PROFIBUS DP-based link
between inverters of the SINAMICS G120 product range and higher-level automation
systems e.g. SIMATIC S7.

Configuration with SIMATIC S7

The layout of the PROFIBUS DP interface and the DIP switches for setting the PROFIBUS
DP address are shown in the Commissioning section.

4.3.1 Setting the PROFIBUS DP address via DIP Switches

Setting the PROFIBUS DP address

Prior to using the PROFIBUS DP interface, the address of the node (inverter) must be set.
There are two methods for setting the PROFIBUS DP address:
● Using the seven PROFIBUS DP address DIP switches on the Control Unit
● Using parameter "P0918".
The PROFIBUS DP address can be set between 1 and 125.

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.

Caution
The 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.
The restart must be initiated by switching the power off and on again irrespective of whether
the Control Unit is supplied with the inverter line supply or its own, separate 24 V connection.

Control Units CU240S

4-10 Operating Instructions, 11/2006, A5E00766042B AA
 Installing/Mounting
4.3 Connecting a CU240S DP or CU240S DP-F via PROFIBUS DP

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 4-1 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

4.3.2 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.

Table 4-2 PIN assignment of the 9-pin sub-D socket

Pin Designation Meaning Range

1 Shield Ground connection
2 U0V Isolated and user supply reference
  3 RxD/TxD-P Receive/send data P (B/B') RS485
4 CNTR-P Control Signal TTL
5 DGND PROFIBUS data reference potential (C/C')
  6 VP Supply voltage positive 5 V ± 10 %
7 U24V Isolated user supply +24 V @ 100 mA
8 RxD/TxD-N Receive/send data N (A/A') RS485
9 - Not assigned
Case Cable shield Cable shield

External 24 V supply
If the PROFIBUS DP interface is required to communicate with the Control Unit when the
Power Module mains power is not present, a 24 V supply must be connected to the Control
Unit terminals 31 (+ 24 V In) and 32 (0 V In).

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 4-11
Installing/Mounting
4.3 Connecting a CU240S DP or CU240S DP-F via PROFIBUS DP

Maximum cable lengths

The PROFIBUS system can handle up to 126 stations. To run all these stations the
PROFIBUS system is divided into segments. All segments have to be connected via
repeater. The maximum number of stations on any segment must not exceed 32.
The maximum cable lengths are dependent on the baud rate (transmission speed). The
maximum cable lengths specified in the table below can be guaranteed only with PROFIBUS
bus cables (for example, Siemens PROFIBUS bus cable, order number 6XV1830-0EH10).

Table 4-3 Permissible cable length for one segment

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.

Control Units CU240S

4-12 Operating Instructions, 11/2006, A5E00766042B AA
 Installing/Mounting
4.3 Connecting a CU240S DP or CU240S DP-F via PROFIBUS DP

Bus connector
To connect the PROFIBUS cable to the PROFIBUS DP interface, a bus connector of one of
the types described in the following table is recommended.

Table 4-4 Recommended PROFIBUS connectors

Order Number 6GK1 500-0FC00 6GK1 500-0EA02

PG socket No No
Max. baud rate 12 Mbaud 12 Mbaud
Terminating resistor On/Off switch On/Off switch
Outgoing cable unit 180° 180°
Interfaces
PROFIBUS nodes 9-pin sub D socket 9-pin sub D socket
PROFIBUS bus cable 4 modular terminals for wires up 4 modular terminals for wires up
to 1.5 mm2 to 1.5 mm2
Connectable PROFIBUS cable 8 ± 0.5 mm 8 ± 0.5 mm
diameter

Note
We recommend only these two connectors since they can be used without difficulty for all
SINAMICS G120 models and are completely compatible in terms of outgoing cable unit
angle.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 4-13
Installing/Mounting
4.3 Connecting a CU240S DP or CU240S DP-F via PROFIBUS DP

Bus terminator
Each bus segment must have a resistor network, i.e. a bus terminator, at both ends.
Where the recommended bus connectors have been used, the bus terminator can be
switched in and out by means of switches as shown in the figure below.

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Figure 4-8 PROFIBUS DP bus termination switch

Using the recommended bus connectors the first and last node on the PROFIBUS network
must be terminated (as shown in the figure below), this switching of the bus terminator
provides both the 220 Ω termination and the 390 Ω biasing. The 390 Ω biasing maintains the
potential difference between the signals in the PROFIBUS network cables.

3/&FRQQHFWRUWHUPLQDWHG
R R R
on on on
off off off

A1 B1 A2 B2 A1 B1 A2 B2

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R
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off

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Figure 4-9 PROFIBUS network with bus termination

Warning
It must be ensured that any node, where the biasing components of the bus are connected,
is powered at all times in which the bus is in operation.

Control Units CU240S

4-14 Operating Instructions, 11/2006, A5E00766042B AA
 Installing/Mounting
4.3 Connecting a CU240S DP or CU240S DP-F via PROFIBUS DP

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.

4.3.3 Screening the bus cable and EMC precautions

Screening the bus cable and EMC precautions

The following EMC-related precautions must be taken to ensure interference-free
PROFIBUS DP operation.

Screening
The screen of the PROFIBUS DP cable must be connected in the bus connector. Additional
screening is provided using a screen clamp on the bus cable screen which must make 360°
contact with the protective earth. The solid copper core must not be scored when the
insulation is removed from the core ends. You must also ensure that the screen of each bus
cable is connected to protective earth at both the cabinet entry point and in the inverter
housing.

Note
The bus cables must be internally twisted and screened, and installed separately from power
cables with a minimum distance 20 cm (7.8 inches). The braided screen and underlying
laminated foil screen (if applicable) must be connected in a 360°, positive connection at both
ends, that is, the screen on the bus cable between two inverters must be connected to the
inverter housing at both ends. The same applies to the screen of the bus cable between the
PROFIBUS DP master and inverter.
Crossovers between bus and power cables must be laid at an angle of 90°.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 4-15
Installing/Mounting
4.3 Connecting a CU240S DP or CU240S DP-F via PROFIBUS DP

Equipotential bonding
Differences in potential (for example, due to different mains supplies) between the inverters
and the PROFIBUS DP master must be avoided.
● Recommended equipotential bonding cables:
– 16 mm2 Cu for equipotential bonding cables up to 200 m long
– 25 mm2 Cu for equipotential bonding cables of over 200 m long.
● Equipotential bonding cables must be routed as close as possible to signal leads; this
means that the area between the bonding conductor and signal lead is as small as
possible.
● Equipotential bonding cables must be contacted in a 360° connection with the earth
electrode/PE conductor.

Control Units CU240S

4-16 Operating Instructions, 11/2006, A5E00766042B AA
 Installing/Mounting
4.4 Connecting a CU240S via USS

4.4 Connecting a CU240S via USS

RS485 Interface
The built-in connector is a 9-way SUB-D female connector for RS485.

Table 4-5 9-way SUB-D connector for RS485

Pin Signal (drive side) Comment

1 Screen Potential equilisation
2 - Unused
3 RS485P Receive- and transmit signal (+)
4 - Unused
5 0V Ground reference
6 5V Supply voltage (output from drive or provided to drive from external)
7 - Unused
8 RS485N Receive- and transmit signal (-)
9 - Unused
X Screen (casing) Potential equilisation
The following connectors can be used for USS connection. Via the switches on the
connectors the RS485 termination can be activated.

Table 4-6 Recommended PROFIBUS connectors

Order Number 6GK1 500-0FC00 6GK1 500-0EA02

PG socket No No
Max. baud rate 12 Mbaud 12 Mbaud
Terminating resistor On/Off switch On/Off switch
Outgoing cable unit 180° 180°

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 4-17
Commissioning (software) 5
5.1 General commissioning information

General commissioning information

The inverter can be adapted to various applications by changing the parameter values.
The parameter values can be changed, using one of the following optional components:
● The OP (Operator Panel), plugged into the Option port of the Control Unit
● The STARTER (Commissioning software via PC) can be connected to the Option port
using a PC connection Kit
● The MMC for downloading complete parameter sets
This section shows how the commissioning of a G120 Inverter is performed using an OP.
The commissioning process using STARTER is driven by dialog boxes and will not be
described in detail in this manual.
The inverter is delivered with identical factory settings for all CU240S control unit; except the
settings of command and setpoint source and values depending on the power module.

Note
Upload and download
• Upload means to save the parameters from the EEPROM of an inverter to a PC (via
STARTER), MMC or an OP.
• Download means to write a parameter set held on a PC, MMC or an OP to the RAM or
EEPROM of an inverter.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 5-1
Commissioning (software)
5.2 Parameters

5.2 Parameters

Overview of parameters
The inverter is adapted to a particular application using the appropriate parameters. This
means that each parameter is identified by a parameter number and specific attributes (e.g.
readable, can be written into BICO attribute, group attribute etc.). Within any one particular
inverter system, the parameter number is unique. On the other hand, an attribute can be
assigned a number of times so that several parameters can have the same attribute.
Parameters can be accessed using the following operator units:
● OP
● PC-based commissioning (start-up) tool "STARTER".
There are two main types of parameters; those that can be altered and those that are read-
only.

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Figure 5-1 Parameter types

Control Units CU240S

5-2 Operating Instructions, 11/2006, A5E00766042B AA
 Commissioning (software)
5.2 Parameters

5.2.1 Write parameters

Description
Parameters which can be written into and displayed are indicated by the prefix "P".
These parameters directly influence the behavior of a function. The value of this parameter is
saved in non-volatile memory (EEPROM) as long as the appropriate option was selected
(non-volatile data save). Otherwise, these values are saved in the volatile memory (RAM) of
the processor, which are lost after power failure or power-off/power-on operations.
Examples of the standard notation used throughout our manuals is given below.

Notation examples:
P0970 parameter 970
P0748.1 parameter 748, bit 01
P0819[1] parameter 819 index 1
P0013[0 ... 19] parameter 13 with 20 indices (indices 0 to 19)

5.2.2 Monitoring parameters

Description
Parameters which can only be monitored are indicated by the prefix "r".
These parameters are used to display internal quantities, for example states and actual
values.

Notation examples:
r0002 monitoring parameter 2
r0052.3 monitoring parameter 52, bit 03
r0947[2] monitoring parameter 947 index 2
r0964[0 ... 4] monitoring parameter 964 with 5 indices (indices 0 to 4)

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 5-3
Commissioning (software)
5.2 Parameters

5.2.3 Parameter Attributes

Overview
In the Parameter List, the header line of each parameter shows all the attributes and groups
for that specific parameter. The figure below shows the details for parameter P0700 and
r1515.

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Figure 5-2 Description of attributes for parameter P0700

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Figure 5-3 Description of attributes for parameter r1515

Index
Using the index, a parameter (e.g. p0013[20]) is defined with several consecutive elements
(in this case, 20). Each individual index is defined using a numerical value.
When transferred to a parameter this means that an indexed parameter can have several
values. The values are addressed using the parameter number including the index value
(e.g. p0013[0], p0013[1], p0013[2], p0013[3], p0013[4], ...).
Indexed parameters are used, for example:
● Drive Data Sets (DDS)
● Command Data Sets (CDS)
● Sub functions.

Control Units CU240S

5-4 Operating Instructions, 11/2006, A5E00766042B AA
 Commissioning (software)
5.2 Parameters

BICO
The following types of connectable parameters are available. A description of BICO
technology is given in the functions chapter.

Table 5-1 Parameter attributes - BICO

BICO Description
BI Binector Input
BO Binector Output
CI Connector Input
CO Connector Output
CO/BO Connector Output/Binector Output

Access level
The access level is controlled using parameter P0003. In this case, only those parameters
are visible at the OP, where the access level is less than or equal to the value assigned in
parameter P0003. On the other hand, for STARTER, only access levels 0 and 3 are relevant.
For example, parameters with access level 3 cannot be changed if the appropriate access
level has not been set.
The following access levels are implemented in the SINAMICS G120 inverter units:

Table 5-2 Parameter attributes - access level

Access level Description

0 User-defined parameter list (refer to P0013)
1 Standard access to the most frequently used parameters
2 Extended access, e.g. to inverter I/O functions
3 Expert access only for experienced users
4 Service access only for authorized service personnel – with password
protection.

Note
In STARTER, all of the user parameters (access stage 3) are always displayed using the
expert list – for the setting p0003 = 0, 1, 2 or 3.
When changing parameters using STARTER, or via a high-level control system, parameter
value changes always become immediately effective.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 5-5
Commissioning (software)
5.2 Parameters

Change state
"P" parameters can only be changed depending on the inverter state. The parameter value is
not accepted if the instantaneous state is not listed in the parameter attribute "Change state".
For instance, the quick commissioning parameter P0010 with the attribute "CT" can only be
changed in quick commissioning "C" or ready "T" but not in operation "U".

Table 5-3 Parameter attributes - Change state

State Description
C Quick commissioning
U Operation (Drive running)
T Drive ready to run

Data types
The data type of a parameter defines the maximum possible value range. Five data types
are used for SINAMICS G120. They either represent an unsigned integer value (U16, U32)
or a floating-point value (float). The value range is frequently restricted by a minimum and
maximum value (min, max) or using inverter/motor quantities.

Table 5-4 Parameter attributes - Data types

Data type Description

U16 Unsigned, integer value with a size of 16 bits
U32 Unsigned, integer value with a size of 32 bits
I16 Signed integer 16-bit value
I32 Signed integer 32-bit value
Float A simple precise floating point value according to the IEEE standard format
max. value range: -3.39e+38 –+3.39e+38

Control Units CU240S

5-6 Operating Instructions, 11/2006, A5E00766042B AA
 Commissioning (software)
5.2 Parameters

Unit
For SINAMICS G120, the units of a particular parameter involve the physical quantity (e.g.
m, s, A). Quantities are measurable properties/characteristics of physical objects, operations,
states and are represented using characters of a formula (e.g. V = 9 V).

Table 5-5 Parameter attributes - Unit

Unit Description
- No dimension
% Percentage
A Ampere
V Volt
Ohm Ohm
us Microseconds
ms Milliseconds
s Seconds
Hz Hertz
kHz Kilohertz
1/min Revolutions per minute [RPM]
m/s Meters per second
Nm Newton meter
W Watt
kW Kilowatt
Hp Horse power
kWh Kilowatt hours
°C Degrees Celsius
m Meter
kg Kilograms
° Degrees (angular degrees)

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 5-7
Commissioning (software)
5.2 Parameters

Grouping
The parameters are sub-divided into groups according to their functionality. This increases
the transparency and allows a quicker and more efficient search for specific parameters.
Furthermore, parameter P0004 can be used to control the specific group of parameters that
are displayed on the OP.

Table 5-6 Parameter attributes - Grouping

Grouping Description Main parameter

area:
ALWAYS 0 all parameters
INVERTER 2 inverter parameters 0200 … 0299
MOTOR 3 motor parameters 0300 … 0399 and
0600 … 0699
ENCODER 4 speed encoder 0400 … 0499
TECH_APL 5 technical applications/units 0500 … 0599
COMMANDS 7 control commands, digital I/O 0700 … 0749 and
0800 … 0899
TERMINAL 8 Analog inputs/outputs 0750 … 0799
SETPOINT 10 Setpoint channel and ramp-function gen. 1000 … 1199
Safety integrated 11 Fail-safe functions 9000 … 9999
FUNC 12 Inverter functions 1200 … 1299
CONTROL 13 Motor open-loop/closed-loop control 1300 … 1799
COMM 20 Communications 2000 … 2099
ALARMS 21 Faults, warnings, monitoring functions 2100 … 2199
TECH 22 Technology controller (PID controller) 2200 … 2399

Active
This attribute is only of importance in conjunction with an OP. The "Yes" attribute indicates
that this value is already accepted when scrolling (when changing the value with or ).
Especially parameters which are used for optimization functions have this property (e.g.
constant voltage boost P1310 or filter time constants). On the other hand, for parameters
with the attribute "First confirm", the value is only accepted after first pressing the key
. These include, for example, parameters where the parameter value can have different
settings/meanings (e.g. selecting the frequency setpoint source P1000).

Table 5-7 Parameter attributes - Active

Active Description
Yes The value becomes valid by either scrolling with or
First confirm The value is only accepted by pressing

Control Units CU240S

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 Commissioning (software)
5.2 Parameters

Note
Parameter values that are changed using STARTER or a higher-level control do not have to
be acknowledged.

Quick commissioning
This parameter attribute identifies as to whether the parameter is included in the quick
commissioning (QC) (P0010 = 1).

Table 5-8 Parameter attributes - Quick commissioning

QC Description
No The parameter is not included in the quick commissioning
Yes The parameter is included in the quick commissioning

Value range
The value range, which is specified as a result of the data type, is restricted by the minimum
and maximum values (min, max) and using the inverter/motor quantities. Straightforward
commissioning is guaranteed in so much that the parameters have a default value. These
values (min, max, def) are so permanently saved in the inverter and cannot be changed by
the user.

Table 5-9 Parameter attributes - Value range

Value range Description

- No value entered (e.g.: "r parameter")
Min Minimum value
Max Maximum value
Def Default value

Data sets
A detailed description for the data sets is given in the respective section

Table 5-10 Data sets

BICO Description
CDS Command data set
DDS Drive data set

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 5-9
Commissioning (software)
5.3 Factory settings

5.3 Factory settings

Factory default settings

The inverter system is shipped from the factory as a Control Unit and a Power Module. The
Control Unit has three or seven LEDs (depending on the type of Control Unit) on the front
panel which display the operating state of the inverter. For commissioning and operation the
control unit has to be fitted to the power module as shown in Chapter 4.
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 (CU240S) See pre-assigned inputs below.
Asyncronous motor P0300 = 1
Self-cooled motor P0335 = 0
Motor overload factor P0640 = 150 %
Setpoint input using analog input 1 P1000 = 2
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

Control Units CU240S

5-10 Operating Instructions, 11/2006, A5E00766042B AA
 Commissioning (software)
5.3 Factory settings

Table 5-11 Pre-assignment of the digital inputs for a CU240S *)

Digital Inputs Terminals Parameter Function Active

Command source* - P0700 = 2 Terminals Yes
Digital Input 0, DI0 5 P0701 = 1 ON/OFF1 Yes
Digital Input 1, DI1 6 P0702 = 12 Reversing Yes
Digital Input 2, DI2 7 P0703 = 9 Fault acknowledge Yes
Digital Input 3, DI3 8 P0704 = 15 Fixed setpoint (direct) No
Digital Input 4, DI4 16 P0705 = 16 Fixed setpoint (direct) No
Digital Input 5, DI5 17 P0706 = 17 Fixed setpoint (direct) No
Digital Input 6, DI6 40 P0707 = 18 Fixed setpoint (direct) No
Digital Input 7, DI7 41 P0708 = 0 Digital input disabled No
Digital Input 8, DI8 42 P0709 = 0 Digital input disabled No
*) With CU240S DP and CU240S DP-F control units, P0700 and P1000 are set to 6 (command
source and setpoint source via PROFIBUS DP).
If all the installation and commissioning requirements are met and the motor data matches
the inverter data, the following is possible with the factory settings, when using a control unit
CU240S:

To start and stop the motor Using DI0 with external switch
To reverse direction of rotation Using DI1 with external switch
To reset faults Using DI2 with external switch
To enter a frequency setpoint Using AI0 with external potentiometer;
the default setting of the AI: Voltage input
To display the actual frequency value Using AO0 as current output
The potentiometer and the external switches can be connected through the inverter internal
power supply, as shown in section "Connecting the Control Unit via terminals".

Notice
If settings have to be made which go beyond the factory settings, then depending on the
complexity of the application, when commissioning the inverter, the particular function
description as well as the parameter list including function charts must be carefully taken into
consideration.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 5-11
Commissioning (software)
5.4 Parameterization with Operator Panel

5.4 Parameterization with Operator Panel

The Operator Panel (OP)

The OP is available as an option to enhance the effectiveness of parameterizing and control
of the inverter. The control signals and speed reference can easily be set by pressing the
appropriate buttons. The OP has the ability to upload and download parameter sets from an
inverter to another inverter.

Figure 5-4 Operator Panel (OP, 6SL3255-0AA00-4BA1)

Fitting the OP to the Control Unit

The OP is fitted to the Control Unit as shown in the figure below. No matter which class of
Control Unit is being used, the process is the same.

Figure 5-5 Fitting the OP to the CU

Control Units CU240S

5-12 Operating Instructions, 11/2006, A5E00766042B AA
 Commissioning (software)
5.4 Parameterization with Operator Panel

5.4.1 Function Keys of the OP

Operator Panel - function keys

Table 5-12 OP keys and their functions

Operator Panel Function Effects

Key
Status The LCD indicates the settings which the drive inverter is presently using.
display
Start motor The inverter is started by pressing the key. This key is deactivated in the default setting.
Parameter P0700 should be changed as follows to activate the key:
OP: P0700 = 1
Stop motor OFF1 When this key is pressed, the motor comes to a standstill within the selected
ramp-down time. It is deactivated in the default setting; to activate → refer to the
"Start motor" key.
OFF2 The motor coasts down to a standstill by pressing the key twice (or pressing
once for a longer period of time). This function is always activated.
Direction To reverse the direction of rotation of the motor, press this key. The opposing direction is
reversal displayed using the minus character (-) or by the flashing decimal point. In the default
setting this function is deactivated. To activate it → refer to the "Start motor" key.
Jog motor In the "Ready to power-on" state, when this key is pressed, the motor starts and rotates
with the pre-set jog frequency. The motor stops when the key is released. When the motor
is rotating, this key has no effect.
Function This key can be used to display additional information.
If you press the key during operation, independent of the particular parameter, for two
seconds, the following data will be displayed:
1. Voltage of the DC current link (designated by d – units V).
2. Output current (A)
3. Output frequency (Hz)
4. Output voltage (designated by o – units V).
5. The value, selected in P0005 (if P0005 is configured so that one of the above pieces
of data is displayed (1 to 4), then the associated value is not re-displayed).
The displays mentioned above are run-through one after the other by pressing again.
Step function
Pressing the button briefly makes the display to jump from any parameter (rXXXX or
PXXXX) to r0000 and vice versa. After quitting an alarm, r0000 will be displayed and the
"jumped from parameter" is forgotten.
Acknowledgement
If alarm and fault messages are present, then these can be acknowledged by pressing
key .
Parameter Parameters can be accessed by pressing this key.
access
Increase When this key is pressed, the displayed value is increased.
value
Reduce When this key is pressed, the displayed value is decreased.
value

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 5-13
Commissioning (software)
5.4 Parameterization with Operator Panel

5.4.2 Changing parameters via OP

Changing parameter with the OP

The description below serves as an example that shows how to change any parameter using
the OP.

Table 5-13 Changing P0003 - parameter access level

Step Result on display

1 Press to access parameters
2 Press until P0003 is displayed
3 Press to display the parameter value
4 Press or to set the required value (set to 3)
5 Press to confirm and store the value
6 All level 1 to level 3 parameters are now visible to the user.

Table 5-14 Changing P0700 an index parameter - setting OP control

Step Result on display

1 Press to access parameters
2 Press until P0719 is displayed
3 Press to access the parameter value
4 Press or to select index 1
5 Press to display actual set value
6 Press or to the required value
7 Press to confirm and store the value
8 Press until r0000 is displayed
9 Press to return the display to the standard drive display (as defined by the customer)

Note
The OP sometimes displays "bUSY" when changing parameter values. This means that the
inverter is presently handling another higher-priority task.

Control Units CU240S

5-14 Operating Instructions, 11/2006, A5E00766042B AA
 Commissioning (software)
5.5 Parameterization with MMC

5.5 Parameterization with MMC

Overview
A G120 inverter can be parameterized by downloading a parameter set from the MMC to the
inverter.
The download can be performed as
● manual download
● automatic download
● start-up download
A detailed download description can be found in the operation section.

Note
The file format for the MMC is FAT. Any other format, such as FAT32 or NTFS are not
compatible with uploading and downloading parameter sets from the inverter.
Formatting can be accomplished using the DOS command line as follows:
C:\>format volume /FS:FAT - where volume has to be replaced by the name of the MMC
drive, for example A
Please keep in mind that formatting will delete all the contents of the MMC.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 5-15
Commissioning (software)
5.6 Parameterization with STARTER

5.6 Parameterization with STARTER

Commissioning with STARTER

The following interfaces - which are Control Unit dependent available:

Table 5-15 Connection possibilities for STARTER

Type USS on RS232 USS on RS485 PROFIBUS DP

PC connected to CU PC Connection Kit Sub D cable & RS485 to DP interface
via RS232 converter
Interface Option port Sub D connector Sub D connector
Restrictions Peer to peer Peer to peer up to 125 slaves
CU240S X X --
CU240S DP X -- X
CU240S DP-F X -- X

General information for connecting STARTER

USS address: see P2011, default setting P2011 = 0
USS baudrate: see P2010, default setting P2010 = 8 (≙ 38400 baud)
PROFIBUS DP address: see P0918 or PROFIBUS DP DIP switches.

STARTER projects
Using STARTER either a new project can be created or an already existing project can be
opened.
To create a new project in STARTER one of the following methods can be used:
● Search inverter
● Wizard
● Select inverter.
When opening an existing project or creating a new project STARTER is in the offline mode.
To go online the button has to be pressed.

Changing parameters with STARTER

Parameters can be changed online or offline (online preferred).
Online parameter changes are stored in the RAM of the inverter. A manual transfer from
RAM to EEPROM can be triggered by pressing . When closing STARTER and the
contents of the RAM and EEPROM are different, the user is asked whether or not they wish
to transfer the RAM data to the EEPROM.

Control Units CU240S

5-16 Operating Instructions, 11/2006, A5E00766042B AA
 Commissioning (software)
5.6 Parameterization with STARTER

Note
Via P0014 the store mode can be changed,
• P0014 = 0: parameter changes stored in RAM (default)
• P0014 = 1: parameter changes stored in EEPROM

Parameter sets that have been changed offline can be transferred to the inverter using the
download button.

Caution
Parameters for fail-safe functions can only be changed in the online mode.
When downloading parameters via STARTER, parameters belonging to fail-safe functions
will not be downloaded.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 5-17
Commissioning (software)
5.7 Commissioning modes

5.7 Commissioning modes

Commissioning overview
Before commissioning is started, the following data must must be available:
● Line supply frequency
● Motor rating plate data
● Command/setpoint sources
● Min./max. frequency or ramp-up/ramp-down time
● Control mode
An example for a rating plate is shown in the figure below. The precise definition and
explanation of this data is defined in DIN EN 60034-1.

3~Mot. 1LA70904-4AA10 H
D-91056 Erlangen E0107/471101 01 001 IEC/EN 60034
16kg IM B3 090L IP55 Th.Cl.F
50 Hz 230/400 V / 60 Hz 460 V
1.5 kW 5.9/3.4 A 1.75 kW 3.4 A
cos 0.81 1420/min cos 0.81 1720/min
220-240/380-420 V / 440-480 V

6.2-5.4/3.6-3.2 A 3.6-3.3 A

Figure 5-6 Example of a typical motor rating plate

Commissioning the inverter with the OP

A differentiation is made between the following scenarios when commissioning the inverter
via OP:
● Quick commissioning
● Motor data identification
● Calculating the motor/control data
● Commissioning the application
● Series commissioning
● Reset parameters to factory settings
● Commissioning the Fail-safe Functions.
When commissioning, initially, a quick or series commissioning should be performed.
If there is no appropriate parameter set available for series commissioning, a quick
commissioning must be carried-out.
With the quick commissioning-function the inverter is adapted to the motor and important
technological parameters are set.

Control Units CU240S

5-18 Operating Instructions, 11/2006, A5E00766042B AA
 Commissioning (software)
5.7 Commissioning modes

Note
Commissioning the inverter with STARTER can be performed via "Configure drive unit".

"Commissioning the application" should only be performed if the inverter–motor combination

provides a satisfactory result.

Common commissioning information

If the inverter is to be commissioned from a defined state, it can be reset to its default
settings by performig a factory reset (see section "Reset parameters to factory settings")
The following check list should help you to commission the Inverter without any problems
and to guarantee a high degree of availability:
● When handling the inverter, carefully observe all of the ESD measures.
● All of the screws must have been tightened up to their specified torque.
● All connectors and option modules must have been correctly inserted, locked or screwed
into place.
● All of the components are grounded/earthed at the points provided and all of the shields
have been connected.
● The Inverter has been designed for defined mechanical, climatic and electrical ambient
conditions. It is not permissible that the specified limit values are exceeded in operation
or when the Inverters are being transported. The following must be carefully observed:
– Line supply conditions
– Pollutant stressing
– Gases which can have a negative impact on the function
– Ambient climatic conditions
– Storage/transport
– Shock stressing
– Vibration stressing
– Ambient temperature
– Installation altitude.
In addition, to carrying-out all of the installation work, an important prerequisite for successful
commissioning is that the Inverter is not disconnected from the line supply while being
parameterized. If a line supply failure interrupts commissioning, then inconsistencies can
occur regarding the parameterization. In this case, it is important that the commissioning is
re-started, possibly with a factory reset to establish the original factory settings.

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Operating Instructions, 11/2006, A5E00766042B AA 5-19
Commissioning (software)
5.7 Commissioning modes

Notice
Behavior of inverter on completion of commissioning
The following behavior should be taken into account when commissioning the inverter:
• standard commissioning with P0014 = 0:
Parameters are only stored in RAM. RAM -> EEPROM can be started:
– with OP: via setting P0971 = 1
– with SATRTER in the online mode: via pressing
RAM -> EEPROM will automatically be performed when starting data transfer from
inverter to MMC (P0802 = 2).
• standard commissioning with P0014 = 1:
All parameter changes will be saved in both RAM and EEPROM.
• While commissioning the fail-safe functions - only possible with a CU240S DP-F - the
relating parameters are automatically stored in RAM and EEPROM
• Data from EEPROM can be transferred to MMC via P0802 = 2.
• Parameters can be changed independent whether an MMC is plugged in or not.
Depending on the settings in P8458 after power cycle the parameters from EEPROM or
MMC are used for start up. The customer has to take of the proper settings of P8458.
– P8458 = 0, no automatic parameter download from the MMC.
– P8458 = 1, automatic parameter download from the MMC only once (at the next start-
up of the CU (default setting)). After the download P8458 is set to 0.
– P8458 = 2, automatic parameter download from the MMC after each start-up of the
CU with plugged-in MMC.

Warning
In case of automatic parameter download from the MMC at start up, F0395 will be
generated.
By acknowledging F0395 the customer automatically agrees to carry out an confirmation test
in standard applications and an acceptance test in fail-safe applications immediately after the
fault was acknowledged.

Control Units CU240S

5-20 Operating Instructions, 11/2006, A5E00766042B AA
 Commissioning (software)
5.7 Commissioning modes

Performing Quick Commissioning via OP

For applications using V/f (P1300 = 0 [default]) or Flux Current Control (FCC) (P1300 = 1 or
6), quick commissioning can be accomplished by setting the following parameters:

Enter the line frequency P0100

Enter the rating label data P0304, P0304, P0305, P0307, P0310 and P0311
Command and setpoint sources P0700, P1000
Minimum and maximum frequency P1080, P1082
Ramp-up and ramp-down times P1120, P1121
Closed-loop control mode P1300
Motor data identification P1900 = 3
For applications using Vector Control (P1300 = 20 … 23), the parameters in the following
flow chart should be set and used:
Parameters designated with an "*" offer more settings than are actually shown here. Refer to
the Parameter list for additional settings.

Table 5-16 Quick commissioning

Parameter Description (Parameter name and factory setting (if not variable) in bold) Setting

P0003 = 3 User access level*

1: Standard: Allows access into most frequently used parameters
2: Extended: Allows extended access e.g. to inverter I/O functions
3: Expert: For expert use only
P0004 = 0 Parameter filter*
0: All parameters
2: Inverter
3: Motor
4: Speed sensor
P0010 = 1 Commissioning parameter filter*
0: Ready
1: Quick commissioning
30: Factory setting
Note: P0010 should be set to 1 in order to parameterize the data of the motor rating plate.
P0100 = 0 Europe/North America (enter the motor frequency)
0: Europe [kW], frequency default, 50 Hz
1: North America [hp]. frequency default, 60 Hz
2: North America [kW], frequency default, 60 Hz
P0205 = 0 Inverter application (enter the required overlaod)
0: High overload (for compressors, processing machines, etc.)
1: Light overload (for pumps and fans, etc.)
Note: This parameter is only effective for Inverters ≥ 5.5 kW/400 V.
P0230 = 0 Output filter (Shows the selected output filter)
0: no filter
1: output choke
3 internal LC filter
4: external output LC filter
P0233 = ? Filter inductance
inductance of the used output filter (phase value)
can only be set, if an external output filter is selected (P230 = 4)

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Operating Instructions, 11/2006, A5E00766042B AA 5-21
Commissioning (software)
5.7 Commissioning modes

Parameter Description (Parameter name and factory setting (if not variable) in bold) Setting

P0234 = ? Filter capacity

Capacity of the used output filter (phase value, if connected in triangle 3*CΔ)
can only be set, if an external output filter is selected (P230 = 4)
P0300 = 1 Select motor type
1: Asynchronous rotational motor
2: Synchronous rotational motor (Note: only V/f control types (P1300 < 20) are permitted)
P0304 = ? Rated motor voltage (enter value from the motor rating plate in V)
The input of rating plate data must correspond with the wiring of the motor (star/delta). This
means, if delta wiring is used for the motor, delta rating plate data has to be entered.
P0305 = ? Rated motor current
enter value from the motor rating plate in A
P0307 = ? Rated motor power
enter value from the motor rating plate in kW or hp
Note: if P0100 = 0 or 2, data is in kW and if P0100 = 1, data is in hp.
P0308 = ? Rated motor cosPhi (only visible if P0100 = 0 or 2)
enter cosϕ from the motor rating plate.
Setting P0308 = 0 causes internal calculation of value.
P0309 = ? Rated motor efficiency (only visible if P0100 = 1)
enter value (%) from the motor rating plate.
Setting P0309 = 0 causes internal calculation of value
P0310 = ? Rated motor frequency
enter value from the motor rating plate in Hz
Pole pair number recalculated automatically if parameter is changed.
P0311 = ? Rated motor speed
enter value from the motor rating plate in RPM)
Setting P0311 = 0 causes internal calculation of value.
Note: Required for vector control and V/f control with speed controller.
Slip compensation in V/f control requires rated motor speed for correct operation.
P0314 = ? Motor pole pair number
1: 2-pole motor
2: 4-pole motor
Recalculated automatically when P0310 (rated motor frequency) or P0311 (rated motor speed)
is changed.
P0320 = ? Motor magnetizing current
Setting P0320 = 0 causes calculation according the setting of P0340 = 1 (data entered from
rating plate) or by P3900 = 1, 2 or 3.
The calculated value is displayed in parameter r0331.
P0335 = 0 Motor cooling
0: Self-cooled using shaft mounted fan attached to the motor
1: Force-cooled, using a separately powered cooling fan
2: Self-cooled and internal fan
3: Force-cooled and internal fan
P0400 = 0 Select encoder type
0: Disabled
2: Quadrature encoder no zero pulse
12: Quadrature encoder & zero pulse
Note: Encoders with zero pulse can also be connected, but the zero pulse is not used.

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 Commissioning (software)
5.7 Commissioning modes

Parameter Description (Parameter name and factory setting (if not variable) in bold) Setting

P0408 = ? Encoder pulses per revolution

Specifies the number of encoder pulses per revolution (encoder resolution)
Note: The encoder resolution is limited by the max. pulse frequency of the encoder circuits
(f_max = 300 kHz).
P0500 = 0 Technological application
Selects technological application
0: High overload
1: Light overload (for pumps and fans, etc. sets internally P1300 = 2)
P0625 = ? Ambient motor temperature
Ambient temperature of motor at time of motor data identification.
Note: It is only allowed to change the value when the motor is cold. A motor identification has
to be made after changing the value.
P0640=150 Motor overload factor
Defines motor overload current limit [%] relative to P0305 (rated motor current).
This defines the limit of the maximum output current as a percentage of the rated motor
current (P0305). This parameter is set, using P0205 for high overload, to 200 % and for light
overload, up to 150 %.
P0700 = 2 Selection of command source*
enter the command source
0: Factory default setting
1: OP (keypad)
2: Terminal (Default for CU240S)
4: USS on RS232
5: USS on RS485
6: Fieldbus (Default for CU240S DP and CU240S DP-F)
P0727 = 0 Selection of 2-/3-wire method
Determines the control method using the terminals.
0: Siemens (start/dir)
1: 2-wire(fwd/rev)
2: 3-wire(fwd/rev)
3: 3-wire(start/dir)
P1000 = 2 Selection of frequency setpoint*
enter the frequency setpoint source
0: No main setpoint
1: MOP setpoint
2: Analog setpoint (Default for CU240S)
3: Fixed frequency
4: USS on RS232
5: USS on RS485
6: Fieldbus (Default for CU240S DP and CU240S DP-F)
7: Analog setpoint 2
P1080 = ? Minimum frequency
Enter the lowest motor frequency (in Hz) to which the motor operates independently of the
frequency setpoint. The value set here is valid for both clockwise and anticlockwise rotation.
P1082 = ? Maximum frequency
Enter the maximum frequency (in Hz) to which the motor is limited independently of the
frequency setpoint. The value set here is valid for both clockwise and anticlockwise rotation.
P1120 = ? Ramp-up time
Enter the time (in seconds) in which the motor should accelerate from standstill up to
maximum motor frequency P1082. If the ramp-up time is set too short, this can cause alarm
A0501 (current limit value) or tripping the inverter with fault F0001(overcurrent).

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Operating Instructions, 11/2006, A5E00766042B AA 5-23
Commissioning (software)
5.7 Commissioning modes

Parameter Description (Parameter name and factory setting (if not variable) in bold) Setting

P1121 = ? Ramp-down time

Enter the time (in seconds) in which the motor should decelerate (using braking) from the
maximum frequency P1082 down to standstill. If the ramp-down time is set too short, this can
cause alarm A0501 (current limit value) or A0502 (overvoltage limit value) or tripping the
inverter with fault F0001 (overcurrent) or F0002 (overvoltage).
P1135 = ? OFF3 ramp-down time
Enter the time (in seconds) in which the motor should decelerate (using braking) from the
maximum frequency P1082 down to standstill with an OFF3 command (fast stop). If the ramp-
down time is set too short, this can cause alarm A0501 (current limit value) or A0502
(overvoltage limit value) or tripping the inverter with fault F0001 (overcurrent) or F0002
(overvoltage).
P1300 = 0 Control mode*
enter the required control mode
0: V/f with linear characteristic
1: V/f with FCC
2: V/f with parabolic characteristic
3: V/f with programmable characteristic
20: Sensorless vector control
21: Vector control with sensor
22: Sensorless vector torque-control
P1500 = 0 Selection of torque setpoint*
enter the source for the torque setpoint
0: No main setpoint
2: Analog setpoint
4: USS on RS232
5: USS on RS485
6: Fieldbus
P3900 = ? End quick commissioning (QC)*
0: No quick commissioning (no motor calculations)
1: Motor calculation and reset of all parameters that haven't been changed to factory settings while QC
process.
2: Motor calculation and reset of all I/O settings to factory settings.
3: Only motor calculation - other parameters are not reset.
Note: If P3900 = 1, 2, or 3 P0340 is set to 1 and the value from P1082 is written into P2000. The appropriate
motor data will be calculated.
While end of quick commissioning is performed "bUSY" will be displayed on the OP. This means that the
control data are being calculated and the respective parameter values are stored in the EEPROM. After
quick commissioning has been completed, P3900 and P0010 will be set to 0.
END End of the quick commissioning/Inverter setting
If additional functions must be implemented for the Inverter, please use the instructions Adaption to the
application and Technological interconnections. We recommend this procedure for motors with a high
dynamic response.

Control Units CU240S

5-24 Operating Instructions, 11/2006, A5E00766042B AA
 Commissioning (software)
5.7 Commissioning modes

Next to "Quick Commissioning"

Next to "Quick Commissioning" the "Motor Data Identification" and additionally in case of
vector mode (P1300 = 20/21) the "Speed Control Optimisation" should be performed.
Both need an ON command to start.

Motor data identification

Warning
The motor data identification routine MUST not be used for loads which are potentially
hazardous (for example, suspended loads for crane applications). Before the motor data
identification routine is started, the potentially hazardous load must be carefully secured (for
example, by lowering the load to the floor or by clamping the load using the motor holding
brake).

Parameter Description (Parameter name and factory setting (if not variable) in bold)
P0625 = ? Ambient motor temperature (entered in °C)
The motor ambient temperature is entered at the instant that motor data is being determined (factory
setting: 20 °C).
The difference between the motor temperature and the motor ambient temperature P0625 must lie in the
tolerance range of approx. ± 5 °C.
Is the motor temperature (P0625) within the tolerance described above? If not the motor must be allowed to cool down.
P0010 = 0 Commissioning parameter filter*
Check if P0010 = 0 (Ready)
P1900 = 3 Select motor data identification*
0: Disabled
2: Identification of all parameters in standstill.
3: Identification of all parameters in standstill including saturation curve
ON command Start motor data identification
Once P1900 ≠ 0, alarm A0541 (motor data identification active) is generated that states, the next ON
command will initiate the motor data identification. When the ON Command is given, current flows through
the motor and the rotor aligns itself.
Note: When motor data identification is complete A0541 will be cleared and P1900 will be set to zero.
OFF1 In order to set the inverter into a defined state, an OFF1 command must be issued before the next step.
END Motor identification is finished.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 5-25
Commissioning (software)
5.7 Commissioning modes

Speed control optimisation

Parameter Description (Parameter name and factory setting (if not variable) in bold)
P0010 = 0 Commissioning parameter filter*
Check if P0010 = 0 (Ready)
P1960 = 1 Speed control optimisation
0: Disable
1: Enable
ON Start Speed control optimisation
command We recommend the Speed control optimisation if vector mode (P1300 = 20 or 21) is selected. Once P1960 =
1, alarm A0542 is generated, that states, the next ON command will initiate the optimisation. If there is a
problem with speed control optimisation due to instability the drive may trip with fault F0042, because no
stable value has been obtained on the ramp up within a reasonable time.
Note: When Speed control optimisation is complete A0542 will be cleared and P1960 will be cleared to zero.

5.7.1 Motor data identification

Motor identification data

The Inverter has a measuring technique which is used to determine the motor parameters:

Equivalent circuit diagram (ECD) ➙ P1900 = 2

Magnetizing characteristic (saturation ➙ P1900 = 3
curve)
For control-related reasons, it is essential that the motor data identification is performed.
Without performing the motor data identification it is only possible to estimate ECD data
using information from the motor rating plate. For example, the stator resistance is extremely
important for the stability of the closed-loop Vector control and for the voltage boost of the V/f
characteristic. The motor data identification routine should be executed, especially if long
feeder cables or if third-party motors are being used.
If the motor data identification routine is being started for the first time, then the following
data is determined, starting from the rating plate data (rated [nominal] data) with P1910 = 1:
● ECD data
● Motor cable resistance
● IGBT on-state voltage and compensation of IGBT gating dead times.
The rating plate data represents the initialization values for the identification. This is the
reason that it is necessary to have the correct input from the rating plate data when
determining the data specified above.

Control Units CU240S

5-26 Operating Instructions, 11/2006, A5E00766042B AA
 Commissioning (software)
5.7 Commissioning modes

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Figure 5-7 Equivalent circuit diagram (ECD)

In addition to the ECD data, the motor magnetizing characteristic (see the figure above) can
be determined using the motor data identification (P1910 = 3). If the motor combination is
operated in the field-weakening range (which is above the nominal frequency of the motor),
then this characteristic should be determined, especially when Vector control is being used.
As a result of this magnetizing characteristic, the Inverter can, in the field-weakening range,
accurately calculate the current which is generated in the field and in-turn achieve a higher
torque accuracy.

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3
3

3

3


3 3  3 3 L w>@
L >$@
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Figure 5-8 Magnetizing characteristic

After selecting the motor data identification using parameter P1910, alarm A0541 is
immediately generated. The motor identification routine is started by the ON command and
different excitation signals are impressed in the motor (DC and AC voltages). This
measurement is carried-out with the motor at a standstill and it takes, including the data
calculation per selection (P1910 = 1 or 3), between 20 seconds and 4 minutes to complete.
The identification time depends on the motor and increases with its size (this takes approx.
4 min. for a 200 kW motor).
The motor data identification routine must be carried-out with the motor in the cold condition
so that the motor resistance values saved can be assigned to the parameter of the ambient

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 5-27
Commissioning (software)
5.7 Commissioning modes

temperature P0625. Only then is the correct temperature adaptation of the resistances
possible during operation.
The motor data identification routine operates with the results of the "Complete
parameterization" P0340 = 1 or the motor equivalent diagram data which was last saved.
The results become increasingly better the more times that the identification routine is
executed (up to 3 times).

Warning
It is not permissible to carry-out the motor identification routine for loads which are potentially
hazardous (e.g. suspended loads for crane applications). Before starting the motor data
identification routine, the potentially hazardous load must be secured (e.g. by lowering the
load to the floor or clamping the load using the motor holding brake).
When starting the motor data identification routine, the rotor can move into a preferred
position. This is more significant for larger motors.

Note
The equivalent circuit data (P0350, P0354, P0356, P0358, P0360) and the motor cable
resistance (P0352) are entered as phase values.
During the motor identification routine, the stator resistance (P0350) and the motor cable
resistance (P0352) are determined.
If the motor cable resistance is known, it should be entered into parameter P0352 after the
motor data identification. The value of P0350 then will be changed in dependenccy of P0352
and is more precisely as the calculated value.
It is not necessary to lock the motor rotor for the motor data identification routine. However, if
it is possible to lock the motor rotor during the identification routine (i.e. by closing the motor
holding brake), then this should be used to determine the equivalent circuit diagram data.
The following formula can be applied to check the correctness of the motor rating plate data:
PN = √3 ∗ VNΥ ∗ INΥ ∗ cosϕ ∗ η ≈ √3 ∗ VNΔ ∗ INΔ ∗ cosϕ ∗ η
Where:
PN rated motor power
VN Υ, VN Δ rated motor voltage (star/delta)
IN Υ, IN Δ rated motor current (star/delta)
cosϕ power factor
η efficiency

Control Units CU240S

5-28 Operating Instructions, 11/2006, A5E00766042B AA
 Commissioning (software)
5.7 Commissioning modes

If Problems occur during the identification run, for example, the current controller oscillates,
then the rating plate data should be re-checked and an approximately correct magnetizing
current P0320 entered. The motor data identification routine should then be re-started by
called P0340 = 1.
Step-by-step table for motor data identification see section "Quick commissioning".

5.7.2 Calculating the motor and control data

Overview
Internal motor/control data is calculated using parameter P0340 or, indirectly using
parameter P3900 or P1910. The functionality of parameter P0340 can, for example, be used
if the equivalent circuit diagram data or the moment of inertia values are known. The
following settings are possible for P0340:

0 No calculation
1 Complete parameterization
2 Calculation of the equivalent circuit diagram data
3 Calculation of V/f and Vector control
4 Calculation of the controller settings
For the complete parameterization (P0340 = 1), in addition to the motor and control
parameters, parameters are also pre-assigned which refer to the motor rated data (for
example, torque limits and reference quantities for interface signals). A complete list of all of
the parameters depending on P0340 is included in the parameter manual.
When calculating the motor/control data using P0340, there are different scenarios, which
can be called-up as a function of the known data.

Note
When exiting quick commissioning with P3900 > 0, internally P0340 is set to 1 (complete
parameterization).
For the motor data identification, after the measurement has been completed, internally
P0340 is set to 3.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 5-29
Commissioning (software)
5.7 Commissioning modes

Performing the calculation of motor and control data via OP

Parameter Description (Parameter name and factory setting (if not variable) in bold) Setting
P0340 = 1 Calculation of motor parameters
This parameter is required during commissioning in order to optimize the operating behavior of
the inverter. For the complete parameterization (P0340 = 1), in addition to the motor/control
parameters, parameters are pre-assigned which refer to the rated motor data (e.g. torque limits
and reference quantities for interface signals). A list of the parameters, which are calculated,
depending on the setting of P0340, are included in the parameter list.
0: No calculation
1: Complete parameterization
2: Calculation of equivalent circuit data
3: Calculation of V/f and Vector control data
4: Calculation of controller settings only
If additional catalog data is known enter the data in P0341, P0342 and P0344.
P0341 = ? Motor inertia [kg*m2]
P0342 = ? Total/motor inertia ratio
P0344 = ? Motor weight (entered in kg)
If the ECD data is known, enter the data in P0350, P0354, P0356, P0358, P0360.
If the ECD data is not known, then: Set P0340 = 4. To calculate the controller settings and skip to END.
P0350 = ? Stator resistance (line) (entered in Ω)
Stator resistance in Ω of the motor which is connected (line). This parameter value doesn't
include the cable resistance.
P0354 = ? Rotor resistance (entered in Ω)
Defines the rotor resistance of the motor equivalent diagram (phase value).
P0356 = ? Stator leakage inductance (entered in mH)
Defines the stator leakage inductance of the motor equivalent diagram (phase value).
P0358 = ? Rotor leakage inductance (entered in mH)
Defines the rotor leakage inductance of the motor equivalent diagram (phase value).
P0360 = ? Main inductance (entered in mH)
Defines the main (magnetizing) inductance of the motor equivalent diagram (phase value).
P0340 = 3 Calculation of motor parameters
3: Calculation of V/f and Vector control
All of the parameters, dependent on the ECD data are calculated and, in addition, the controller
settings (P0340 = 4).
END The motor parameters have been calculated and it is now possible to return to the additional
parameterization in the Section "Adaptation to the application".

Control Units CU240S

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 Commissioning (software)
5.7 Commissioning modes

5.7.3 Commissioning the application

Commissioning the application

After the motor - Inverter combination has been commissioned using quick commissioning,
the following parameters should be adapted and set according to the requirements of your
specific application. As an example, the following points should be considered:
● Functional requirements of the inverter (for example, closed-loop process control with PID
controller)
● Limit values
● Dynamic requirements
● Starting torques
● Load surge requirement
● Overload
● Diagnostics.
If the application includes a function, which is not covered by the quick commissioning, then
the "Function" section in this manual or the parameter list should be consulted.

Note
In the factory setting, parameter changes are stored in the volatile memory of the inverter
(RAM). To safe the changes in the EEPROM one of the following methods can be used:
• Set P0014 = 1 all changes stored immediately in the EEPROM
• start data transfer from RAM to EEPROM via P0971 = 1 (when using OP) via (with
STARTER).
The durartion of the data transfer depends on the number of changed parameters. In some
cases it can last up to 3 minutes.
With the OP data transfer is displayed with "bUSY".
When using STARTER it is displayed via a progress bar. The sucessful transfer is displayed
via a dialog box.

Commissioning the application - flow charts

The parameters designated with an "*" offer more setting possibilities than are listed here.
Refer to the parameter list for additional setting possibilities.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 5-31
Commissioning (software)
5.7 Commissioning modes

General settings

Parameter Description (Parameter name and factory setting (if not variable) in bold) Setting
P0003 = 3 User access level*
1: Standard: Allows access into most frequently used parameters.
2: Extended: Allows extended access e.g. to inverter I/O functions
3: Expert: For expert use only
P0210 = ? Supply voltage (enter the voltage in V)
This parameter enters the real line supply voltage to which the Inverter is connected. Only
necessary if P1254 = 0 (default: P1254 = 1).
P0290 = 2 Inverter overload reaction
This defines the response of the Inverter to an internal overtemperature.
0: Reduce output frequency
1: Trip (F0004)
2: Reduce pulse frequency and output frequency
3: Reduce pusle frequency then trip (F0004)
P0335 = 0 Motor cooling (enter the motor cooling system)
0: Self-cooled using the shaft mounted fan attached to the motor
1: Force-cooled using the separately powered cooling fan
2: Self-cooled and internal fan
3: Force-cooled and internal fan

Pulse Encoder

Parameter Description (Parameter name and factory setting (if not variable) in bold) Setting
P0400 = 0 Select encoder type *
or 0: Disabled (no encoder fitted)
P0400 = ? 2 or 12: Two quadrature encoder (two channels)
P0408 = ? Number of encoder pulses (Only if encoder is fitted)
Enter the number of encoder pulses per revolution. The number of encoder pulses per
revolution P0408 is limited by the maximum pulse frequency of the pulse encoder module
(fmax = 300 kHz)

Control Units CU240S

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 Commissioning (software)
5.7 Commissioning modes

Temperature Sensor

Parameter Description (Parameter name and factory setting (if not variable) in bold) Setting
P0601 = 0 Motor temperature sensor
or 0: No sensor (→ P0610)
P0601 = ? 1: PTC thermistor (→ P0604)
2: KTY84 (→ P0604)
P0604 = ? Threshold motor temperature
Enter the warning threshold for motor overtemperature protection. The trip temperature
(threshold) is where either the inverter is tripped or Imax is reduced (P0610) which is always
10 % above the warning threshold.
P0610 = 2 Motor I2t temperature reaction
Defines the reaction when the mtor temperature reaches the warning threshold.
0: No reaction, only a warning
1: Warning and Imax reduced (this results in a reduced output frequency)
2: Warning and trip (F0011)

Temperature calculation without sensor

In the vector control mode (P1300 = 20/21/22/23) Temperature calculations is possible
without sensor. The following parameters have to be set.

Parameter Description (Parameter name and factory setting (if not variable) in bold) Setting
P0621= 1 Motor temperature identification after restart
0: No identification
1: Temperature identification only at first "motor on" after power cycle
2: Temperature identification at each motor on.
P0622 = Motor magnetizing time for temperature identification after stator restistance identification
This parameter will be initialised with a value for one calculating cycle of the motor
temperature. It depends on the identified rotor time constant. Due to accuracy reasons this
calculation may be performed several times.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 5-33
Commissioning (software)
5.7 Commissioning modes

Selection of command source

The available command sources depend on the used CU.
Default setting on the control unit used the command source is set per default to different
values.

Parameter Description (Parameter name and factory setting (if not variable) in bold) Setting
P0700 = 2/6 Selection of command source
This selects the digital command source
0: Factory default setting
1: OP (keypad)
2: Terminal (P0701 … P0709), factory setting for CU240S
4: USS on RS232
5: USS on RS485 (not available with CU240S DP and CU240S DP-F)
6: Fieldbus (P2050 … P02091), factory setting for CU240S DP and CU240S DP-F, not
available with CU240S)

Control Units CU240S

5-34 Operating Instructions, 11/2006, A5E00766042B AA
 Commissioning (software)
5.7 Commissioning modes

Assigning digital input functions

Parameter Description (Parameter name and factory setting (if not variable) in bold) Setting
P0701 = 1 Terminal 5: factory settings for Possible values for P0701 to P0709:
Digital Input 0 (DI0) CU240S 0: Digital input disabled
P0702 = 12 Terminal 6: 1: ON/OFF1
Digital Input 1 (DI1) 2: ON reverse /OFF1
P0703 = 9 Terminal 7: 3: OFF2 - coast to standstill
Digital Input 2 (DI2) 4: OFF3 - quick ramp-down
9: Fault acknowledge
P0704 = 15 Terminal 8: 10: JOG right
Digital Input 3 (DI3) 11: JOG left
P0705 = 16 Terminal 16: 12: Reverse
Digital Input 4 (DI4) 13: MOP up (increase frequency)
P0706 = 17 Terminal 17: 14: MOP down (decrease frequency)
Digital Input 5 (DI5) 15: Fixed frequency selector bit0
16: Fixed frequency selector bit1
P0707 = 18 Terminal 40: factory settings for 17: Fixed frequency selector bit2
Digital Input 6 (DI6) CU240S 18: Fixed frequency selector bit3
P0708 = 0 Terminal 41: not availble with 25: DC brake enable
Digital Input 7 (DI7) CU240S DP-F 27: Enable PID
P0709 = 0 Terminal 42: 29: External trip
Digital Input 8 (DI8) 33: Disable additional freq setpoint
99: Enable BICO parameterization
P0724 = 3 Debounce time for digital inputs
Defines the debounce time (filtering time) used for digital inputs.
0: No debounce time
1: 2.5 ms debounce time
2: 8.2 ms debounce time
3: 12.3 ms debounce time
P9603 = 00 Terminal 62, 63: SLS via FD1A and FD1B not availble with CU240S and CU240S DP
P9603 = 01 Terminal 60, 61: SLS via FD0A and FD0B
P9603 = 02 Terminal 62, 63: SS1 via FD1A and FD1B
P9603 = 03 Terminal 60, 61: SS1 via FD0A and FD0B
P9603 = 04 Terminal 62, 63: STO via FD1A and FD1B
P9603 = 05 Terminal 60, 61: STO via FD0A and FD0B

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 5-35
Commissioning (software)
5.7 Commissioning modes

Assigning digital output functions

Parameter Description (Parameter name and factory setting (if not variable) in bold) Setting
P0731 = 52:3 BI: function of digital output 0 (DO0), defines the source for digital output 0
Terminal 18: DO0, NC/Terminal 19: DO0, NO/Terminal 20: DO0, COM
52:3 Inverter fault active
P0732 = 52:7 BI: function of digital output 1,defines the source for digital output 1
Terminal 21: DO1, NO/Terminal 22: DO1, COM
52:7 Inverter warning active
P0733 = 0:0 BI: function of digital output 2, defines the source for digital output 2
Terminal 23: DO0, NC/Terminal 24: DO0, NO/Terminal 25: DO0, COM
0:0 Digital output disabled
P0748 Invert digital outputs
Bits 0, 1 and 2 can be used to invert the signals of digital outputs 0, 1 and 2

Frequency setpoint set

Parameter Description (Parameter name and factory setting (if not variable) in bold) Setting
P1000 = ? Selection of frequency setpoint
0: No main setpoint
1: MOP setpoint (P1031 … P1040)
2: Analog setpoint (P0756 … P0762), factory setting for CU240S
3: Fixed frequency (P1001 … P1023)
6: Fieldbus (P2050 … P02091), factory setting for CU240S DP and CU240S DP-F, not
available with CU240S)
7: Analog setpoint 2
10: Additional setpoint (1 = MOP) + Main setpoint (0 = No main setpoint)
11: Additional setpoint (1 = MOP) + Main setpoint (1 = MOP)
12: Additional setpoint (1 = MOP) + Main setpoint (2 = Analog setpoint)
…
62: Additional setpoint (6 = Fieldbus) + Main setpoint (2 = Analog setpoint)
63: Additional setpoint (6 = Fieldbus) + Main setpoint (3 = Fixed frequency)
…

Frequency setpoint via MOP (P1000 = 1)

Parameter Description (Parameter name and factory setting (if not variable) in bold) Setting
P1031 = 0 Setpoint memory of the MOP
The last motorized potentiomenter setpoint, which was active before the OFF command or
switching-off, can be saved.
0: MOP setpoint will not be stored
1: MOP setpoint will be stored in P1040
P1032 = 1 Inhibit reverse direction of MOP
0: reverse direction is allowed
1: Reverse direction inhibited
P1040 = 5 Setpoint of the MOP
Defines the setpoint [Hz] of the motorized potentiometer (MOP).

Control Units CU240S

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 Commissioning (software)
5.7 Commissioning modes

Frequency setpoint via analog input (AI) (P1000 = 2)

Parameter Description (Parameter name and factory setting (if not variable) in bold) Setting
P0756 = 0 AI type
Defines the type of the analog input and also enables analog input monitoring.
0: Unipolar voltage input (0 to +10 V)
1: Unipolar voltage input with monitoring (0 V … +10 V)
2: Unipolar current input (0 mA … 20 mA)
3: Unipolar current input with monitoring (0 mA … 20 mA)
4: Bipolar voltage input (-10 V … +10 V)
NOTE: The following applies for P0756 … P0760:
Index 0: Analog input 0 (AI0), terminals 3 and 4
Index 1: Analog input 1 (AI1), terminals 10 and 11
3!
P0757 = 0 Value x1 of AI scaling [V/mA] 33__ !3!3
P0758 = 0.0 Value y1 of AI scaling 
this parameter represents the value of x1 as a 
percentage of P2000 (reference frequency) $63PD[
K

P0759 = 10 Value x2 of AI scaling [V/mA]

P0760 = 100 Value y2 of AI scaling 3

This parameter represents the value of x2 as

a percentage of P2000 (reference frequency)
3 9
P$
9 [
3 3 P$
3
3 3

$63PLQ

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 5-37
Commissioning (software)
5.7 Commissioning modes

Frequency setpoint via fixed frequency (P1000 = 3)

Parameter Description (Parameter name and factory setting (if not variable) in bold) Setting
P1016 = 1 Fixed frequency mode, defines The fixed frequency can be selected via four digital
the selection method for fixed inputs (default DI3 … DI6).
frequencies. Fixed frequences via direct selection (P1016 = 1):
1: direct selection With the default settings additional combinations as
2: binary coded follows are possible:
P1001 = 0 Fixed frequency 1, (FF1) )L[HG)UHTXHQF\ ))3DU ))
Value given in Hz. VHOHFWHGYLD >+]@
P1002 = 5 Fixed frequency 2
',3  3GHIDXOW +] 
P1003 = 10 Fixed frequency 3 ',3  3GHIDXOW +] 
3GHIDXOW +]
P1004 = 15 Fixed frequency 4 ',3  
',3  3GHIDXOW +] 
P1005 = 20 Fixed frequency 5 ',', 33 
33
P1006 = 25 Fixed frequency 6 ',', 
',', 33 
P1007 = 30 Fixed frequency 7 ',', 33 
33
P1008 = 35 Fixed frequency 8 ',', 
',',', 333 
P1009 = 40 Fixed frequency 9 ',',', 333 
333
P1010 = 45 Fixed frequency 10 ',',', 
',',',', 3333 
P1011 = 50 Fixed frequency 11 Fixed frequences via binary coded selection
P1012 = 55 Fixed frequency 12 (P1016 = 2):
With binary coded selection each frequency, set in one
P1013 = 60 Fixed frequency 13
of the parameters P1002 … P1015 can be directly
P1014 = 65 Fixed frequency 14 selected.
P1015 = 65 Fixed frequency 15 Fixed Frequency FF-default
FF-
setting
P1020 = 722.3 Fixed frequency selection - Bit 0 selected via Par
[Hz]
Selects DI3 for FF selection
DI3 (P1020 =722.3) P1001 0
P1021 = 722.4 Fixed frequency selection - Bit 1 DI4 (P1021 =722.4) P1002 5
Selects DI4 for FF selection DI5 (P1022 =722.5) P1003 10
P1022 = 722.5 Fixed frequency selection - Bit 2 DI6 (P1023 =722.6) P1004 15
DI3, DI4 P1005 20
Selects DI5 for FF selection
DI4, DI5 P1006 25
P1023 = 722.6 Fixed frequency selection - Bit 3 DI5, DI6 P1007 30
Selects DI6 for FF selection DI3, DI5 P1008 35
DI4, DI6 P1009 40
DI3, DI6 P1010 45
DI3, DI4, DI5 P1011 50
DI4, DI5, DI6 P1012 55
DI3, DI5, DI6 P1013 60
DI3, DI4, DI6 P1014 65
DI3, DI4, DI5, DI6 P1015 65

Control Units CU240S

5-38 Operating Instructions, 11/2006, A5E00766042B AA
 Commissioning (software)
5.7 Commissioning modes

Analog outputs

Parameter Description (Parameter name and factory setting (if not variable) in bold) Setting
P0771 = 21 CI: Analog output
Defines the function of the 0 mA … 20 mA analog output
21: CO: actual frequency (scaled according to P2000)
24: CO: actual output frequency (scaled according to P2000)
25: CO: actual output voltage (scaled according to P2001)
26: CO: actual DC-link voltage (scaled according to P2001)
27: CO: Output current (scaled according to P2002)
NOTE: The following applies for P0771 … P0785:
Index 0: analog output 0 (AO0), terminals 12 and 13
Index 1: analog output 1 (AO1), terminals 26 and 27
P0775 = 0 Permit absolute value
Decides if the absolute value of the analog output is used.
If enabled, this parameter will take the absolute value of the value to be outputed.
If the value was originally negative then the corresponding bit in r0785 is set.
P0776 = 0 Type of analog output
Scaling of r0774.
0: Current output
1: Voltage output
NOTE: P0776 changes over the scaling of r0774 (0 mA … 20 mA ⇔ 0 V … 10 V).
Scaling parameters P0778, P0780 and the deadband are always entered in 0 mA … 20 mA.
Analog output 0 can be switched to a voltage output with a range 0 … 10 V.
Analog output 1 is only a current output. When it is used as voltage output, it must be
terminated using a 500 Ω resistor.
P0777 = 0.0 Value x1 of the analog output scaling
Defines x1 output characteristic in percentage. This parameter represents the lowest analog
value as a percentage of P200x (depending on the setting of P0771).
P0778 = 0 Value y1 of the analog output scaling
This parameter represents the value of x1 in mA. P$

P0779 = 100 Value x2 of the analog output scaling 

This defines x2 of the output characteristic in percentage.

3
This parameter represents the highest analog value as a \
percentage of P200x (depending on the setting of P0771).
3
P0780 = 20 Value y2 of the analog output scaling \
This parameter represents the value of x2 in mA.
P0781 = 0 Width of analog output deadband  3
[
3
[
 

This sets the width of the deadband in mA for the analog

output.

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Operating Instructions, 11/2006, A5E00766042B AA 5-39
Commissioning (software)
5.7 Commissioning modes

JOG frequency

Parameter Description (Parameter name and factory setting (if not variable) in bold) Setting
P1057 = 1 JOG Enable
P1057 = 0 JOG-function diabled
P1057 = 1 JOG-function enabled
P1058 = 5 JOG frequency right
Frequency in Hz when the motor is being jogged in the clockwise direction of roatation.
P1059 = 5 JOG frequency left
Frequency in Hz when the motor is being jogged in the counter-clockwise direction of rotation.
I
P1060 = 45 JOG ramp-up time
Ramp-up time in seconds from 0 to the 3
IPD[
maximum frequency (P1082). The JOG ramp-up
is limited by P1058 or P1059. 3

P1061 = 50 JOG ramp-down time

Ramp-down time in seconds from the maximum
frequency (P1082) to 0.
W
3 3

Additional Setpoints

Parameter Description (Parameter name and factory setting (if not variable) in bold) Setting
P1074 = 1.0 BI: disable additional setpoint
P1075 = 775 CI: additional setpoint
Defines the source of the additional setpoint which is added to the main setpoint.
Common settings:
755: Analog input setpoint
1024: Fixed frequency setpoint
1050: MOP setpoint
P1076 = 1.0 CI: additional setpoint scaling
Defines the source to scale the additional setpoint.
Common settings:
1: Scaling of 1.0 (100 %)
755: Analog input setpoint
1024: Fixed frequency setpoint
1050: MOP setpoint

Control Units CU240S

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 Commissioning (software)
5.7 Commissioning modes

Skip Frequency

Parameter Description (Parameter name and factory setting (if not variable) in bold) Setting
P1091 = 7.5 Skip frequency 1 (entered in Hz)
Avoids mechanical resonance effects and suppresses (skips) IRXW
frequencies in the range around the skip frequency ± P1101
(skip frequency bandwidth).
P1092 = 0.0 Skip frequency 2
P1093 = 0.0 Skip frequency 3
P1094 = 0.0 Skip frequency 4
P1101 = 1.0 Skip frequency bandwidth (entered in Hz)

3
6NLSIUHTXHQF\

Ramp times

Parameter Description (Parameter name and factory setting (if not variable) in bold) Setting
I
P1120 = 10 Ramp-up time
Enter the acceleration time in seconds. 3
IPD[
P1121 = 10 Ramp-down time I
Enter the deceleration time in seconds.

W
3 3

Rounding

Parameter Description (Parameter name and factory setting (if not variable) in bold) Setting
P1130 = 5.0 Ramp-up initial rounding time (in seconds) The rounding times are recommended, as
P1131 = 5.0 Ramp-up final rounding time (in seconds) abrupt responses can be avoided therefore
reducing stress and damage to the
P1132 = 5.0 Ramp-down initial rounding time (in seconds) mechanical system.
P1133 = 5.0 Ramp-down final rounding time (in seconds) The ramp-up and ramp-down times are
P1134 = 0 Rounding type extended by the component of the rounding
0: continuous smoothing (jerk-free) ramps.
1: Discontinuous smoothing
NOTE: for discontinuous rounding (P1134 = 1),
after the setpoint is reduced or an OFF1
command, the final rounding at ramp-up (P1131)
and the initial rounding at ramp-down (P1132)
are not executed.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 5-41
Commissioning (software)
5.7 Commissioning modes

Parameters to set before finishing the application setting

The following parameters should be configured for each application.

Parameter Description (Parameter name and factory setting (if not variable) in bold) Setting
P1800 = 4 Pulse frequency (kHz)
The pulse frequency can be changed in 2 kHz steps. The range extends from 4 kHz up to
16 kHz. The complete inverter output current at 50 °C is reached with 4 kHz.
The maximum output frequency is limited by the pulse frequency. Operation up to 266 Hz is
possible with a pulse frequency of 4 kHz. If a higher output frequency is required, then the
pulse frequency should also be increased (10 kHz pulse frequency - maximum output
frequency of 650 Hz)
If low-noise operation is not required, then the inverter losses and the high-frequency
disturbances emitted by the inverter can be reduced by selecting lower pulse frequencies.
P2000 = 50 Reference frequency (Hz)
The reference frequency in Hertz corresponds to a value of 100 %.
This setting should be changed if a maximum frequency of higher than 50 Hz is required.
NOTE: This scaling acts on the maximum frequency of the analog setpoints, fixed frequencies
and motorized potentiometer normalization operations are referred to 100 %.
P2001 = 1000 Reference voltage (V)
The reference voltage in Volts (output voltage) corresponds to a value of 100 %.
NOTE: This setting should only be changed if it is necessary to output the voltage with another
scaling.
P2002 = ? Reference current (A)
The reference current in Apmeres (output current) corresponds to a value of 100 %. Factory
setting is 200 % of the rated motor current (P0305).
NOTE: This setting should only changed if it is necessary to output the current with another
scaling.
P2003 = ? Reference torque (Nm)
The reference torque in Newton-metres corresponds to a value of 100 %. Factory setting is
200 % of the rated motor torque, determined from the motor data, for a constant motor torque.
NOTE: This setting should only changed if it is necessary to output the torque with another
scaling.
P2004 = ? Reference power (kW or hp)
The reference power in kW or hp corresponds to a value of 100 %. Factory setting is 200 % of
ther rated motor power at constant motor torque.
This setting should only be changed if it is necessary to output the power with another scaling.
bUSY Once the save command is given, "bUSY" will be displayed
END When the save is completed, the display will return to normal and parameterization is complete.

Control Units CU240S

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 Commissioning (software)
5.7 Commissioning modes

Finishing the application setting

Parameter Description (Parameter name and factory setting (if not variable) in bold) Setting
P0971 = 1 Transfer data from RAM to EEPROM
0: Disabled
1: Start data transfer, RAM → EEPROM
All of the parameter changes are transferred from the RAM into the EEPROM which means
that they are saved in a non-volatile state within the Inverter (data is not lost when the power
fails).
While the transfer is active, "bUSY" will be displayed on the OP. Once the transfer is
completed P0970 will be set internally to "0" and the "P0970" will be displayed.
Note: Data transfer RAM → EEPROM is not necesarry when the commissioning is performed
via the OP, because all parameter settings are stored in EEPROM immediately when changed
by the OP.

5.7.4 Series Commissioning

Overview
Series commissioning means the possibility to transfer the parameter set from one inverter
into a number of other inverters which allows fast commissioning for identical applications
(for example series machines or group inverters).
The series commissioning is divided into the following steps:
● create a valid parameter set
● upload this parameter set
● download of the uploaded parameter set into the new inverter
To perform series commissioning an appropriate parameter set must be available. This
parameter set can be created by parameterizing an Inverter via OP or STARTER.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 5-43
Commissioning (software)
5.7 Commissioning modes

Caution
Parameter download between different types of control units and of different firmware
versions is not recommended.
It is possible to download parameter sets from different CU types, however, as the
parameter sets might differ, the user is fully responsible for the consistency of the
downloaded parameter set.
Therefore, the customer has to confirm his responsibility in case of an automatic download
by acknowledging F0395.
During download of a parameter set from an MMC to the EEPROM of the Control Unit
CU240S (e.g. during serial commissioning) you have to note that the LEDs are flashing
correctly. If the Control Unit CU240S is in a fault state, the LEDs indicate this fault state with
higher priority than the download. It is not sure that the parameter set is downloaded
correctly.

Once an inverter with an appropriate parameter set is available, the parameter set can be
uploaded and in the next step downloaded into the new inverter via OP, STARTER or MMC.
The various interfaces are shown in the figure below.

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Figure 5-9 Series commissioning interfaces

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5-44 Operating Instructions, 11/2006, A5E00766042B AA
 Commissioning (software)
5.7 Commissioning modes

Warning
For series commissioning, all of the communication interfaces as well as also the digital and
analog interfaces are re-initialized. This results in a brief communications failure or causes
the digital outputs to switch.
Potentially hazardous loads must be carefully secured before starting a series
commissioning.
Potentially hazardous loads can be secured as follows before starting series commissioning:
• Lower the load to the floor, or
• Clamp the load using the motor holding brake.

Note
Upload
Before the upload starts, the parameters will be copied from RAM to EEPROM
Manual and automatic download
With a manual download all necessary parameters excluding the fail-safe parameters (only
with CUs with fail-safe functions) are downloaded into the inverter. A manual download can
be triggered by the customer as described in the following.
With an automatic download even the fail-safe parameters are downloaded into the inverter.
An automatic download can only be performed with an MMC.
An automatic download can be performed at Start-up or by swapping an inverter component
(CU or PM), details are described in the following sections and in the chapter "Operation" of
this manual.

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Operating Instructions, 11/2006, A5E00766042B AA 5-45
Commissioning (software)
5.7 Commissioning modes

Note
Restrictions to be considered when performing upload and download:
• Only the parameter set stored in the EEPROM of the inverter is uploaded.
• Fail-safe parameters cannot be uploaded via OP or STARTER.
• Once the upload or download procedure has started, it should not be interrupted.
• Parameter download from a standard CUs to a CUs with fail-safe functions and vice
versa is not possible.
• During the up or download all LEDs are flashing (the "BF" LED is not relevant). After
finishing that process successfully the "RDY" LED is on.
• During the upload process any data already held by the OP is overwritten.
• If the download fails, the inverter will not function correctly and the "SF" LED (red) is on.
– Possible fault messages in case of download failure with OP
F0055, F0056, F0057 or F0058
– Possible fault messages in case of download failure with MMC
F061, F0062 or F0063

Notice
After upload and download of parameters between differing Control Units, the parameter
settings must be checked.
Parameter download from a different CU might fail with F0063 if parameters cannot be
downloaded (Check P949 for the (first) parameter number which cannot be downloaded).
If F0061 or F0063 occurs during startup it cannot be cleard except via a power cycle.

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 Commissioning (software)
5.7 Commissioning modes

5.7.4.1 Series commissioning with the OP

Upload and download a parameter set with an OP

With an OP a single parameter set can be uploaded from an inverter and then downloaded
into another inverter.
To copy a parameter set from one inverter to another, the following procedure should be
performed.

Upload a parameter set with an OP

Prerequisites
● An inverter with an apropriate parameter set is available (upload inverter)
● Supply voltage is active for the upload inverter
● The upload inverter is in "Ready State".

Parameter Description (Parameter name and factory setting (if not variable) in bold) Setting
Fit the OP to the Inverter - for the parameter set to be uploaded, perform the following steps:
P0003 = 3 User access level*
1: Standard: Allows access into most frequently used parameters
2: Extended: Allows extended access e.g. to inverter I/O functions
3: Expert: For expert use only
P0010 = 30 Commissioning parameter*
0: Ready
1: Quick commissioning
2: Inverter
30: Factory setting, parameter transfer
95: Safety commissioning (for CUs with fail-safe functions only)
P0802 = 1 Transfer data from EEPROM
0: Disabled
1: Start OP transfer
2: Start MMC Transfer
While the upload is active "bUSY" will be displayed on the OP and the inverter will not react to
any commands.
If the upload has been completed successfully, P0010 and P0802 will be set to 0 and the OP
display will return to normal.
If the upload has failed, F00055 (failure while saving parameter on OP) or F00057 (OP fault)
will be displayed.
In this case attempt another upload.
After a successful upload disconnect the OP from the upload inverter.

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Operating Instructions, 11/2006, A5E00766042B AA 5-47
Commissioning (software)
5.7 Commissioning modes

Download a parameter set with an OP

Prerequisites
● Supply voltage is active for the download inverter
● The download inverter is in "Ready State".

Parameter Description (Parameter name and factory setting (if not variable) in bold) Setting
Fit the OP to the inverter and perform the download according the flow chart.
P0003 = 3 User access level*
1: Standard: Allows access to the most frequently used parameters
2: Extended: Allows extended access e.g. to inverter I/O functions
3: Expert: For expert use only
P0010 = 30 Commissioning parameter*
0: Ready
1: Quick commissioning
2: Inverter
30: Factory setting, parameter transfer
95: Safety commissioning (for CUs with fail-safe functions only)
P0803 = 1 Transfer data to EEPROM
0: Disabled
1: Start OP transfer
2: Start MMC Transfer
While the download is active "bUSY" will be displayed on the OP and the inverter will not
react to any commands.
If the download has been completed successfully, P0010 and P0803 will be set to 0 and the
OP display will return to normal.
If the download has failed, F00055 (failure while saving parameter to EEPROM), F00057 (OP
fault) or F00058 (OP contents incompatible) will be displayed.
In this case attempt another download or perform a factory reset to allow the inverter to return
to a known state.
After a successful download the OP can be removed and connected to another inverter for
download. Then perform the download steps again until the series commissioning has been
completed for all inverters.

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 Commissioning (software)
5.7 Commissioning modes

5.7.4.2 Series commissioning with STARTER

Upload a parameter set with STARTER

Prerequisites
● An inverter with an apropriate parameter set is available (upload inverter)
● STARTER is installed on the PC used for series commissioning
● Supply voltage is active for the upload inverter
● The upload inverter is in "Ready State".
Connect the STARTER PC via the Option Port (USS on RS232, peer to peer) to the upload
inverter (PC connection Kit requiered), press the online button and perform the upload by
activating the button .

Note
Upload with STARTER to MMC
If you want to upload a parameter set with STARTER to an MMC, P0010, P0802 must be set
via the expert list.

Download a parameter set with STARTER

Prerequisites
● Supply voltage is active for the download inverter
● The download inverter is in "Ready State".
Connect the STARTER PC via the Option Port (USS on RS232, peer to peer) to the
download inverter (PC connection Kit requiered), press the online button and perform the
download by activating the button . The data set must be saved in the EEPROM.

Note
If you want to perform an manual download of a parameter set with STARTER from an
MMC, P0010, P0803 and P0804 must be set via the expert list.

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Operating Instructions, 11/2006, A5E00766042B AA 5-49
Commissioning (software)
5.7 Commissioning modes

5.7.4.3 Inserting and removing the MMC

Inserting the MMC

To insert an MMC into the Control Unit of the inverter, the process shown in the figure below
should be performed.

6,1$0,&6

6,1$0,&6

Figure 5-10 Installing the MultiMedia Card (MMC)

Warning
When inserting an MMC during operation Alarm A0564 appears if P8458 is set to 0. This is a
hint that with P8456 = 0 no automatic download will be performed at startup.
If the MMC is inserted to perform an upload this alarm can be quitted without any further
action.
If the MMC is inserted to perform an automatic download P8456 must be set accordingly.

Control Units CU240S

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 Commissioning (software)
5.7 Commissioning modes

Removing the MMC

To remove the MMC from the Control Unit, the following procedure should be performed:
1. Using a thin-bladed screwdriver, push down the release-catch on the MMC housing.
2. Grasp the MMC gently and pull upwards.
This procedure is shown in the figure below.

6,1$0,&6

6,1$0,&6

Figure 5-11 Removing the MMC from the Control Unit

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 5-51
Commissioning (software)
5.7 Commissioning modes

5.7.4.4 Series commissioning with MMC

Upload and download a parameter set with an MMC

A parameter set can be uploaded from an inverter and then downloaded into another
inverter. The following important restrictions must be considered when using the copying
procedure:
● An inverter with an apropriate parameter set is available (upload inverter)
● The upload inverter can be accessed via OP, STARTER or PROFIBUS
● An MMC Type 6SL3254-0AM00-0AA0 is available.

Note
During a parameter download from a MMC to the EEPROM of the Control Unit (e.g.
during serial commissioning) normally the LEDs are flashing.
If the Control Unit is in a faulty state, the fault will be displayed by the LEDs (SF on, RDY
off), although the download is performed.
If the parameter download has been performed successfully F0395 appears.

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 Commissioning (software)
5.7 Commissioning modes

Upload a parameter set with an MMC

Prerequisites
To perform a series commissioning with the MMC the following conditions must be fullfiled:
● Supply voltage is active for the upload inverter
● The upload inverter is in "Ready State".

Note
Before uploading, the parameters will be copied from RAM to EEPROM

Parameter Description (Parameter name and factory setting (if not variable) in bold) Setting
Insert the MMC to the inverter - for the parameter set to be uploaded, perform the following
steps:
P0010 = 30 Commissioning parameter*
0: Ready
1: Quick commissioning
2: Inverter
30: Factory setting, parameter transfer
95: Safety commissioning (for CUs with fail-safe functions only)
P0804 = ? Select Clone file
0: clone00.bin
…
99: clone99.bin
Note: Via P0804 the name of the clone file can be selected. Theoretically up to 100 (0 … 99)
parameter sets can be stored on an MMC.
P0802 = 2 Transfer data from EEPROM
0: Disabled
1: Start OP Transfer
2: Start MMC Transfer
If the upload has been completed successfully, P0010 and P0802 will be set to 0 and the
"RDY" LED is on.
If the upload has failed, F0061 (MMC-PS not fitted) will be displayed, LED "SF" (red) is on.
In this case insert an MMC and attempt another upload.
After a successful upload remove the MMC from the upload inverter.

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Operating Instructions, 11/2006, A5E00766042B AA 5-53
Commissioning (software)
5.7 Commissioning modes

Manual Download of a parameter set with an MMC

Note
The following important restrictions should be considered when using the download
procedure:
• During the download the inverter will not react to any commands.
• Once the download procedure has started, it cannot be interrupted.
• After upload and download of parameters between differing Control Units, parameter
settings must be checked.
• Parameter download from a different CU might fail with F0063 if parameters cannot be
downloaded (Check P949 for the (first) parameter number which cannot be downloaded).
• If the download fails, the inverter reverts to the previous parameters from the EEPROM.

Prerequisites
● Supply voltage is active for the download inverter
● The download inverter is in "Ready State".

Parameter Description (Parameter name and factory setting (if not variable) in bold) Setting
Insert the MMC to the download inverter and perform the manual download according the flow
chart.
P0010 = 30 Commissioning parameter*
0: Ready
1: Quick commissioning
2: Inverter
30: Factory setting, parameter transfer
95: Safety commissioning (for CUs with fail-safe functions only)
P0804 = ? Select Clone file (for download)
0: clone00.bin
…
99: clone99.bin
P0803 = 2 Transfer data to EEPROM
0: Disabled
1: Start OP Transfer
2: Start MMC Transfer
If the download has been completed successfully, P0010 and P0803 will be set to 0 and the
"RDY" LED is on.
If the upload has failed, F0061 (MMC-PS not fitted) or F0062 (MMC-PS contents invalid) resp.
F0063 (MMC-PS contents incompatible) will be displayed, LED "SF" (red) is on.
In this case insert a proper MMC and attempt another download or perform a factory reset.
After a successful manually download remove the MMC from inverter and insert it to the next
download inverter. Then perform the download steps again until the series commissioning has
been completed for all inverters.

Control Units CU240S

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 Commissioning (software)
5.7 Commissioning modes

Automatic Download
The automatic download at start-up is controlled via P8458. With the automatic download all
necessary parameters including the parameters regarding fail-safe functions are downloaded
into the inverter.

Note
MMC for "automatic download"
For an automatic download always the file clone00.bin will be used.
The user has to take care, that clone00.bin (saved as "clone00.bin" with STARTER on PC or
via setting P0804 = 00 with the OP) is available on the MMC, used for an automatic
parameter download at start-up. Otherwise automatic download will not be processed.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 5-55
Commissioning (software)
5.7 Commissioning modes

Power ON

QR yes go to
swap?
Swap behavior

QR yes
MMC plugged?

QR P8458 > 0? yes

(Clone Control)

yes valid Par. QR

set?/Safety settings
compliant?

QR P8458 = 1? yes
(Clone Control)

P7844 = 1? yes
P8458 = 0
(acceptance test/
(Clone Control)
confirmation)
QR
QR
Power Stack type
compliant?

yes adjust CU parameters

according to
Power Stack data

F0395

wait for
MMC fault
Ready acceptance test /
F0061/F0063
confirmation

Figure 5-12 Automatic download - overview

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 Commissioning (software)
5.7 Commissioning modes

The possible settings for P8458 and their functions are given below.

P8458 = 0: Automatic parameter download from the MMC is inhibited.

P8458 = 1: Automatic parameter download from the MMC only once (at the next start-up
of the CU (default setting)). After the download P8458 is set to 0.
P8458 = 2: Automatic parameter download from the MMC after each start-up of the
control unit.

Successful automatic download

After a successful automatic download, F0395 will be displayed.
● In case of a standard CU a confirmation is necessary.
● In the case of CUs with fail-safe functions, an acceptance test must be performed.
Confirmation
On standard CUs the current parameter set needs to be checked and confirmed by clearing
F0395. It can be cleared via:
● Digital input or PLC signal (depends on the settings of P0700)
● setting P7844 = 0.
● Pressing the FN button on the OP

Warning
The user is responsible for ensuring that the parameters held in the CU are the correct
parameters for their application.

Acceptance test
On CUs with integrated fail-safe functions it is necessary to do an acceptance test (refer to
the "Fail-safe functions" section in this manual). To clear F0395 on CUs with integrated fail-
safe functions the following procedure has to be followed:
● P0010 = 30
● P9761 = fail-safe password
● P7844 = 0
● Carry out acceptance test

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Operating Instructions, 11/2006, A5E00766042B AA 5-57
Commissioning (software)
5.7 Commissioning modes

Automatic download fault

If the automatic download process fails, the CU will return to the parameter set previously
held in the EEPROM and the following fault codes are generated:

Table 5-17 Automatic download fault codes

Fault code Description

F0061 Automatic download of parameters was not successful.
F0063 Automatic download of parameters was not successful (e.g. wrong CU).
In this case check, whether the MMC is defective or a parameter set clone00.bin is available
or the parameter set is valid.
A valid parameter set means, it is not from a different type (eg. CU20S DP and CU240S or
failsafe and standard CUs)

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5.7 Commissioning modes

5.7.5 Reset parameters to factory settings

Overview
With a factory setting a defined initial state of all of the inverter parameters can be realized.
You can re-establish the initial state by carrying-out a factory via p0970. The factory setting
values are designated as "Factory setting" in the parameter list.
After a factory reset, the inverters have the following basic settings:
CUs with RS485 interface (no PROFIBUS interface)
● Control using the digital inputs
– ON/OFF using DI0
– Direction of rotation reversal using DI1
– Fault acknowledgement using DI2.
● Setpoint input using analog input 0
● Signal output using the digital outputs
– Fault active using DO0
– Warning active using DO1.
● Actual frequency using the analog output
● The basic V/f characteristic is the control mode (P1300 = 0)
● Asynchronous motor (P0300 = 1).
CUs with PROFIBUS interface
● For the PROFIBUS variants the command source and setpoint source will be set to
PROFIBUS communication.
● The basic V/f characteristic is the control mode (P1300 = 0)
● Asynchronous motor (P0300 = 1).
Note
When resetting the parameters to the factory setting, the communications memory is re-
initialized. This means that communications are interrupted for the time it takes to perform
the reset.

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Commissioning (software)
5.7 Commissioning modes

Warning
Fail-safe parameters
When using Standard CUs, only the factory reset with P0970 = 1 must be taken into
account.
When using CUs with fail-safe functions two reset methods are available:
• P0970 = 1 resets only non fail-safe function relating parameters (application
parameters).
If a factory reset with P0970 =1 is performed on a Control Unit with fail-safe functions
all application parameters will be reset, previous parameters settings regarding fail-
safe functions remain unchanged. This means, no acceptance test has to be
performed.
• P0970 = 10 (password protected) resets only fail-safe function relating parameters
If parameters regarding fail-safe functions must be changed, an acceptance test has
to be performed.

Reset to the factory setting

Parameter or action Description (Parameter name and factory setting (if not variable) in bold)
P0003 = 1 User access level*
1: Standard: Allows access into most frequently used parameters.
P0004 = 0 Parameter filter
0: All parameters
P0010 = 30 Commissioning parameter*
30: Factory setting, parameter transfer
P0970 = 1 Factory reset*
1: Parameter reset to the default values
BUSY (on OP) The inverter carries-out a parameter reset (duration, approx. 10 s) and then automatically
Progress bar (STARTER) exits the reset menu and sets
P0970 = 0: Disabled
P0010 = 0: Ready

Note
The following parameters will not be changed with a factory reset:
• P0014 Store mode
• P0100 Europe / North America
• P0201 power stack code number
• Communication parameters (USS and PROFIBUS settings)
• Data depending on actual Power module

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5.8 Commissioning the Fail-safe Functions

5.8 Commissioning the Fail-safe Functions

Available fail-safe functions

● Safe Torque Off (STO)
● Safe Stop 1 (SS1)
● Safely Limited Speed (SLS)
● Safe Brake Control (SBC).
The signals for STO, SS1 and SLS are connected to the Control Unit, an EM-Brake is
connected to the Power Module.

Command source for fail-safe functions

As command source for the fail-safe signals either the fail-safe terminals (60 … 63) or
PROFIsafe can be used (see p9603 and p9803).

Warning
PROFIsafe address
The PROFIsafe address is per default identical to the PROFIBUS address. Due to safety
reasons it must be changed to a different value.
It must especially differ from the address determined by the DIP switches (see following
tables).
The PROFIsafe address needs to be changed as well in P9810 of the inverter as in the
higher level control system (in case of SIMATIC S7 in HW config), otherwise F1640 will
occur.

Note
Via terminal you can use up to two of the three fail-safe functions (STO, SS1 and SLS) while
via PROFIsafe all three functions are available.

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5.8 Commissioning the Fail-safe Functions

Behavior of PROFIBUS and PROFIsafe address

The behavior of PROFIBUS address (P0918) and PROFIsafe address (P9810) is shown in
the following tables:

Case DIP switch P0918 P9810 Behavior

setting value value
1 0 B B PROFIBUS and PROFIsafe address identical and Not allowed
determined by P0918.
2 0 B C PROFIBUS and PROFIsafe address differ. ok
Setting C is valid for PROFIsafe address.
Setting B is valid for PROFIBUS.
3 A A C PROFIBUS and PROFIsafe address differ. ok
Setting C is valid for the PROFIsafe address.
Setting A (from DIP switch) is valid for PROFIBUS.
4 A A A PROFIBUS and PROFIsafe address identical and Not allowed
determined by the DIP switch.

With changing the addresses the following is valid:

Case DIP switch P0918 P9810 DIP switch setting

setting value value
1 0 B1→B2 B1→B2 PROFIsafe address would also change from B1 to B2 Not allowed
when PROFIBUS address is changed as it is identical to
P0918.
2 0 B1→B2 C Although, PROFIBUS address is changed from B1 to B2, ok
the PROFIsafe address remains C as it differs from
P0918.
3 0 B B→C Parameter P9810 is initially identical to P0918. ok
Only the PROFIsafe address changes from B to C.
4 A1→A2 A1→A2 A1→A2 PROFIBUS and PROFIsafe address would change from Not allowed
A1 to A2 after power cycle.
5 A1→A2 A1→A2 C The PROFIsafe address remains at C. ok
Only PROFIBUS address changes from A1 to A2 after
power cycle.
6 A A A→C Parameter P9810 initially identical to P0918. ok
Only the PROFIsafe address changes from A to C.

Warning
In particular, it must be observed that the PROFIsafe address is not determined by the DIP
switches (Case 4). In this case a possible hardware fault of the DIP switches will cause a
change of the PROFIsafe address.

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Commissioning parameters regarding fail-safe functions

Parameters regarding fail-safe functions can only be accessed on a Control Unit with fail-
safe functions, on a Standard CU this parameters are not available. For safety reason
parameters are handled by pairs and stored on two separate processors within the CU with
fail-safe functions.
When commissioning of fail-safe functions is completed, checksums for each processor data
are created. These checksums are permanently compared. If they differ, the inverter initiates
a latched safe torque off (LSTO) state and stops the system.
The access level of the fail-safe function parameters is 3, therefore set P0003 = 3, when
using an OP.
To enter the commissioning mode for fail-safe functions set parameter P0010 = 95.
When the safety commissioning mode is initiated a password must be set in parameter
P9761. The default password for the system is 12345, it is highly recommended that this
password is changed to ensure complete security of the fail-safe function parameters. More
detailed description of this process is given in the following flow charts.
The commissioning process of fail-safe functions would normally be accomplished with the
use of either the STARTER software or the optional Operator Panel (OP).
When a parameter is modified, the relevant value is transmitted to the relevant processor in
the CU. The value is transmitted back to the user interface and can be checked by the
processor and the user for correctness.
To complete commissioning of fail-safe functions use parameter P3900 = 10, which accepts
all the changes to the fail-safe parameters. All values stored on both processors are checked
and if no discrepancies are found the inverter state will change from "safety commissioning"
to "ready".
If, however, a discrepancy is found safety commissioning can not be finished. The fault
number will be shown in r0947. In this case interrupt the safety commissioning with P3900 =
11 to reload to the former stored settings. To reset all fail-safe parameters to their default
values set P0970 = 10.
If a fault is made during safety commissioning, and the system is in an undefined state, it is
recommended to perform a safety reset with P0970 = 10.
When changing fail-safe parameters, each parameter will be written to the P1 processor and
its equivalent parameter to the P2 processor, for example:
● P9603 – enables the selection of the required safe digital input terminals or PROFIsafe
communications for P1 processor.
● P9803 – enables the selection of the required safe digital input terminals or PROFIsafe
communications for P2 processor.

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5.8 Commissioning the Fail-safe Functions

To select the PROFIsafe communications, following actions would be performed:

1. P9603 would be set to the value 128.
2. The system would read the change, process the information to the drive processor
memory and verify that the information has been received correctly.
3. P9803 would be set to the value 128.
4. The system would read the change, process the information to the communication
processor memory and verify that the information has been received correctly.
5. Once both write actions have been verified by the system, a checksum is created.
When commissioning has been completed, a checksum for all the data held in both
memories is created and continually checked to verify the integrity of the data.

Notice
Behavior of inverter on completion of commissioning
The following behavior should be noted when commissioning the inverter:
• After commissioning the fail-safe functions the fail-safe parameters are automatically
stored in the RAM and EEPROM.
• If an MMC is plugged into the CU, this is not affected by normal commissioning or
commissioning the fail-safe functions.
• To save the EEPROM content on a MMC, a transfer EEPROM to MMC via P0802 = 2
must be performed.
• After commissioning the fail-safe functions, an acceptance test must be carried out.

5.8.1 Parameters for fail-safe functions

Parameters for fail-safe functions

The following table gives an overview of all parameters for fail-safe functions. Fail-safe
parameters have access level 3 (P0003 = 3). To modify values of fail-safe parameters a
password is required (P9761). A detailed description is given in the parameter list.
Since there are two processors on CUs with integrated fail-safe functions, they will be
distinguished as follows:
● The drive processor will be termed as P1
● The communications processor will be termed as P2.

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5.8 Commissioning the Fail-safe Functions

Table 5-18 Parameters for fail-safe functions

Parameter Description Unit Default Min. Max.

value value value
Drive processor
P9601 SI enable parameter - 2 0 2
P9602 SI enable safe brake monitoring - 0 0 1
P9603 SI Selection of Safety Source - 0 0 128
P9650 SI Safe Digital Input debounce delay time ms 50 0 2000
P9651 SI Safe Digital Input filter delay time ms 5 0 100
P9659 SI maximum time until test stop h 8.0 0.1 8760.0
r9660 SI remaining time until test stop h - - -
P9680 SI braking ramp delay ms 250 10 99000
P9681 SI braking ramp down time ms 10000 100 99000
P9682 SI minimum speed for standstill detection Hz 5.0 2.0 20.0
P9690 SI setpoint for SLS Hz 10.0 1.0 300.0
P9691 SI tolerance for SLS Hz 13.0 5.0 302.0
P9692 SI response to selecting SLS - 1 0 2
r9760 SI internal password - 12345 1000 99999
P9761 SI input password - 0 1000 99999
P9762 SI change password - 0 1000 99999
P9793 SI change password confirmation - 0 1000 99999
r9770 SI Firmware version - - - -
r9771 SI hardware functions - - - -
r9772 SI status word - - - -
r9798 SI display checksum - 0000h 0000h FFFFh
P9799 SI parameter checksum - 0000h 0000h FFFFh
P9810 PROFIsafe destination address - 0 0 65534
Communication processor
P9801 SI enable parameter - 2 0 2
P9802 SI enable safe brake monitoring - 0 0 1
P9803 SI Selection of Safety Source - 0 0 128
P9850 SI Safe Digital Input debounce delay time s 0.050 0.000 2.000
P9851 SI Safe Digital Input filter delay time s 0.005 0.000 0.100
P9880 SI braking ramp delay s 0.250 0.010 99.000
P9881 SI braking ramp down time s 10.000 0.100 99.000
P9882 SI minimum speed for standstill detection kHz 0.005 0.002 0.020
P9890 SI setpoint for SLS kHz 0.010 0.001 0.300
P9891 SI tolerance for SLS kHz 0.013 0.005 0.302
P9892 SI response to selecting SLS - 1 0 2
r9898 SI display checksum - 0000h 0000h FFFFh
P9899 SI parameter checksum - 0000h 0000h FFFFh

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5.8 Commissioning the Fail-safe Functions

5.8.2 Password for fail-safe functions

Password for fail-safe functions

There are four parameters associated with the password protection system. All these
parameters require level 3 access (only important when using OP) – the parameters are as
follows:
● r9760 – shows the currently valid password for fail-safe function parameters.
● P9761 – used to enter the password.
● P9762 – used for entering a new password (5 digits with no leading zero (0)).
● P9763 – used to confirm a new password.
When a password is entered (5 digits with no leading zero), it is compared with the password
held in r9760.
If correct, access is granted.
If incorrect, the parameters for fail-safe functions will be locked out and the user will have to
manually exit the commissioning mode for fail-safe functions by using parameter P3900 = 11
which cancels all previous changes to the parameters for fail-safe functions.
To change the password see "General steps for commissioning of fail-safe functions"

5.8.3 Checksums

Checksums
All parameters for fail-safe functions are verified by the use of checksums. These checksums
ensure the integrity of the data held within the drive processors memory.
There are four checksum, two for each of the processors, these are:
● r9798 – actual checksum for P1.
● P9799 – reference checksum for P1.
● r9898 – actual checksum for P2.
● P9899 – reference checksum for P2.

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5.8 Commissioning the Fail-safe Functions

5.8.4 General steps for commissioning fail-safe functions

General steps to change fail-safe funcitons

The parameters designated with an "*" offer more setting possibilities than are listed here.
Refer to the parameter list for additional setting possibilities.
The following steps must always be carried-out when changing fail-safe functions:

Parameter Description Unit Default Min. Max.

P0003 = 3 User access level* 1 0 4
3: Expert: For expert use only
P0010 = 95 Commissioning parameter* 0 0 95
95: Commissioning the fail-safe functions
P9761 SI input password - 0 1000 99999
The safety password is entered in this parameter to get access to
change fail-safe function parameters.
Change requested fail-safeparameters, then finish the parameterization with the following steps:
P9799 Checksum for SI parameters - 000h 000h FFFFh
Checksum of the fail-safe function parameters.
Enter value of r9798
P9899 Checksum for SI parameters - 000h 000h FFFFh
Checksum of the fail-safe function parameters.
Enter value of r9898
P3900 = 10 End of the safety commissioning* 0 0 11
10: Accept changes of fail-safe function parameters
11: Cancel changes of fail-safe function parameters

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5.8 Commissioning the Fail-safe Functions

5.8.5 Common step-by-step descriptions for fail-safe functions

Change password

Parameter Description Unit Default Min. Max.

P9761 SI input password - 0 1000 99999
The safety password is entered in this parameter to get access to
change the fail-safe parameters.
P9762 SI change password - 0 1000 99999
Enter the new password. The password must have 5 digits but no
leading zero (0).
P9763 SI change password confirmation - 0 1000 99999
The new password must be confirmed here. If P9762 and P9763 are
the same, then this value is written into r9760. In the future, fail-safe
parameters can be accessed by entering this password into P9761.

Enabling fail-safe functions

Parameter Description Unit Default Min. Max.

P9601 = ? SI enable parameter - 2 0 2
Fail-safe parameter for enabling the individual fail-safe control
functions.
Bit 00 = 1/0: Reserved
Bit 01 = 1/0: Activation/deactivation of the forced dynamisation after
STO
P9801 = ? SI enable parameter - 2 0 2
Refer to P9601

Enable fail-safe brake monitoring

Parameter Description Unit Default Min. Max.

P9602 = ? SI enable safe brake monitoring - 0 0 1
0: Disable monitoring of safe brake control
1: Enable monitoring of safe brake control
P9802 = ? SI enable safe brake monitoring - 0 0 1
Refer to P9602

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5.8 Commissioning the Fail-safe Functions

Select fail-safe command source

Parameter Description Unit Default Min. Max.

P9603 = ? SI Selection of Safety Source - 0 0 128
Fail-safe parameter for selection of the fail-safe input signals. The fail-
safe input signals can be taken either from PROFIsafe or from the
digital inputs of G120.
Selects either safe digital inputs or PROFIsafe .
• Bit 00 = 1/0: SLS activated/deactivated via FDI1A and FDI1B
• Bit 01 = 1/0: SLS activated/deactivated via FDI0A and FDI0B
• Bit 02 = 1/0: SS1 activated/deactivated via FDI1A and FDI1B
• Bit 03 = 1/0: SS1 activated/deactivated FDI0A and FDI0B
• Bit 04 = 1/0: STO activated/deactivated FDI1A and FDI1B
• Bit 05 = 1/0: STO activated/deactivated FDI0A and FDI0B
• Bit 07 = 1/0: SLS, SS1 and STO activated/deactivated via
PROFIsafe
Note:
• If Bit 07 = 1, all other bits must be set 0
P9803 = ? Selection of safety command source - 0 0 128
Refer to P9603

Consistency check time of fail-safe digital inputs

Parameter Description Unit Default Min. Max.

P9650 = ? Safe input debounce delay time ms 50 0 2000
Defines the maximum allowed debounce delay between the two safe
digital input pins. If both safe digital inputs are not consistent after this
time a fault will be generated (1600.108 or 1600.208).
P9850 = ? Safe input debounce delay time s 0.050 0.000 2.000
Refer to P9650.

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5.8 Commissioning the Fail-safe Functions

Filter time of fail-safe digital inputs

Parameter Description Unit Default Min. Max.

P9651 = ? Safe input filter delay time ms 5 0 1000
Defines the response time delay of the safe digital inputs. Signals that
are shorter than the specified time are not processed as fail-safe
signals but ignored. Any noise shorter than the parameterised filter
time will not trigger a fail safe function at the related fail safe digital
input.
P9851 = ? Safe input filter delay time s 0.005 0.000 1.000
Refer to P9650.

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5.8 Commissioning the Fail-safe Functions

Test stop interval setting

Parameter Description Unit Default Min. Max.

P9659 = ? SI maximum time until test stop* h 8.0 0.1 8760.0
The time interval between test stops is specified. The remaining time
until a test stop is required is shown in r9660. When r9660 reaches
zero, the time interval has expired and warning A1699 is activated.
The warning solely informs that a test stop is required. The user
should activate a test stop on the next occasion. The drive
functionality will not be affected by the warning.
The test stop is activated in the following cases:
• after each power-up
• on selecting the STO when Bit 01 in P9601/P9801 is set
• when leaving the latched safe torque off (LSTO).
During the test stop the shutdown paths are checked and a processor
selftest runs. The timer for the forced dynamisation (see r9660) is
reset to the default value specified in P9659 and warning A1699 is
cleared under the following conditions:
• after reducing P9659 below the current value in r9660,
• after each power-up
• on selecting the STO when Bit 01 in P9601/P9801 is set and the
test is complete
• when leaving the LSTO when the test is complete.
The default value is 8 hours.
Note:
For safety reasons, it is necessary to initiate the safe standstill as a
test at intervals of maximum one year in order to check the operability
of the fail-safe system. Thus, at the latest one year after the last
activation of the safe standstill the inverter sets a status bit (r9772,
Bit 15) and generates warning A1699. The process control (i.e. PLC)
must then initiate the STO at the next opportunity, for example, when
the drive has already a short phase with zero speed. Provided the
dynamisation has not been deactivated (see parameters
P9601/P9801, Bit 01), the fail-safe hardware is tested once the safe
standstill is active. If the inverter returns the "Safe torque off (STO)
selected" (r9772, Bit 01) status signal, the safe standstill can be
released again since part of the test is continued in the background.
The immediate switch-on will be inhibited for approximately 2.4
seconds. Once the self test is complete the dynamisation bit (Bit 15 of
r9772) is cleared automatically. The higher level control (i.e. PLC)
must log the setting and clearing of the status bit and the dynamisation
bit. To detect errors while writing and storing safety-relevant data, the
control should fetch cyclically at 8 hour intervals all safety-related
parameters and compare them with the expected values. Should there
be a difference, the fail-safe signals (STO or SS1) should be used to
initiate a safe standstill and to issue a fault message.
This action must also be logged appropriately.

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5.8 Commissioning the Fail-safe Functions

Safe Stop 1 setting

Parameter Description Unit Default Min. Max.

P9680 = ? SI braking ramp delay ms 250 10 99000
Time [in ms] between selecting the safe braking ramp (SBR) and the
activation of the monitoring ramp. The actual frequency is compared to
the frequency of the monitoring ramp when the SBR is active. If the
actual frequency exceeds that of the monitoring ramp, an latched safe
torge off (LSTO) is generated. For applications with changing loads,
an increase of P9680/P9880 or P9691/P9891 is recommended. A
larger deviation of the actual frequency from the reference is then
acceptable.
Note:
A value of 99000 would deactivate the SBR monitoring, this value
therefore is not allowed. Set P9880 accordingly. The ramping on
selection of SLS or SS1 will however still follow the ramping time in
P9681/P9881.
P9880 = ? SI braking ramp delay s 0.250 0.010 99.000
Refer to P9680.
P9681 = ? SI braking ramp-down time ms 10000 100 99000
Defines the braking ramp-down time for the dafe braking ramp (SBR)
in seconds. The ramp-down time is used for the SBR and the
monitoring ramp. The total braking time Tx can be derived where fx is
the current frequency according to the following formulas:
a) For activation of the SLS: Tx = P9681 * (fx - P9690)/200 Hz
b) For activation of SS1: Tx = P9681 * (fx - P9682)/200 Hz
Note:
In contrast to other ramping times (e.g. p1120, p1121), the SI braking
ramp-down time is referred to 200 Hz and not to p1082. See formulas
above.
P9881 = ? SI braking ramp-down time s 10.000 0.100 99.000
Refer to P9681.
P9682 = ? SI minimum speed for standstill detection Hz 5.0 2.0 20.0
A speed below the threshold of P9682/P9882 is considered as
standstill. If the SS1 has been selected, the safe standstill (STO) will
be activated.
P9882 = ? SI minimum speed for standstill detection kHz 0.005 0.002 0.020
Refer to P9682.

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Safely-limited Speed

Parameter Description Unit Default Min. Max.

P9690 SI setpoint for SLS Hz 10.0 2.0 300.0
Speed setpoint that is used when the safely limited speed (SLS) is
selected. Depending on the setting in P9692/P9892 the frequency of
P9690/P9890 may also serve as a speed threshold instead of a
setpoint (see P9692).
Note:
For applications with changing loads, an increase of P9680/P9880 or
P9691/P9891 is recommended. If the "safely limited speed" (SLS) is
selected while the actual speed is below the setpoint value, Bit 04 and
Bit 05 will be set simultanously in r9772.
P9890 SI setpoint for SLS kHz 0.010 0.002 0.300
Refer to P9690.
P9691 SI tolerance for SLS Hz 13.0 5.0 302.0
Upper tolerance margin for the SLS. If the actual frequency at initiation
of the safely limited speed lies below the value of P9691/P9891 and
later on exceeds that value an latched safe torque off (LSTO) is
generated. The tolerance defined by the difference P9691 to P9690
(or P9891 to P9890) is also used for the monitoring ramp when the
SBR is active. For applications with changing loads it is recommended
to increase P9691/P9891.
Note:
The value in P9691 needs to be larger than the value in P9690. This
condition is checked when leaving the safety commissioning.
P9891 SI tolerance for SLS kHz 0.013 0.005 0.302
Refer to P9691.
P9692 SI response to selecting SLS - 1 0 2
Response if, after the initiation of safely limited speed (SLS), the
speed is higher than the limit value:
• 0:
Activation of the speed monitoring and disabling the set value
channel. If the actual speed at initiation of SLS exceeds the
parameterized speed limit the latched safe torque off is initiated.
• 1
Braking to the set speed with safe braking ramp, then activation of
the monitoring function and disabling the set value channel.
• 2
The monitoring is activated at once. If the actual speed at initiation
of SLS exceeds the parameterized speed limit the latched safe
torque off is initiated. The set value channel is not disabled.
P9892 SI response to selecting SLS - 1 0 2
Refer to P9692.

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5.8 Commissioning the Fail-safe Functions

5.8.6 Safety factory reset

Safety factory reset

The safety factory reset sets all fail-safe parameters to its default value except the following:
● P9760 SI internal password
● P9761 SI input password
● P9762 SI change password
● P9763 SI change password confirmation

Procedure for resetting the fail-safe related parameters

Parameter Description (Parameter name and factory setting (if not variable) in bold)
P0003 = 3 User access level*
1: Standard: Allows access into most frequently used parameters.
2: Extended: Allows extended access e.g. to inverter I/O functions
3: Expert: For expert use only
P0004 = 0 Parameter filter*
0: All parameters
P0010 = 30 Commissioning parameter*
0: Ready
30: Factory setting, parameter transfer
P9761 SI input password
Enter the safety password
P0970 = 10 Factory reset*
0: Disabled
1: Parameter reset
10: Safety reset
BUSY (on OP) The inverter carries-out a reset of the fail-safe related parameters (duration, approx. 10 s)
and then automatically exists the reset menu and sets
P0010 = 0: Ready
P0970 = 0: Disabled

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5.8 Commissioning the Fail-safe Functions

5.8.7 Acceptance Test and Acceptance Log

Description
In order to verify the parameters for the fail-safe functions, an acceptance test must be
carried-out after commissioning, reset and also when changing a completely backed-up data
set of the parameters for the fail-safe functions (e.g. by MMC). This acceptance test must be
appropriately logged and documented. An example for an appropriate acceptance log is
included in the Appendix. The acceptance logs should be adequately archived.

Acceptance test
The machinery construction company (OEM) must carry-out an acceptance test for the fail-
safe functions that have been activated at the machine.

Authorized person, acceptance log

Appropriately authorized personnel must test each of the fail-safe functions. These must be
documented/logged in an acceptance log and must be signed. The acceptance log must be
inserted/attached in/to the logbook of the machine
Authorized in this case means a person from the machinery construction company (OEM)
that as a result of their training and knowledge regarding the fail-safe functions, can
appropriately carry-out an acceptance test.

Note
The information/instructions and descriptive information regarding commissioning in Section
"Commissioning the fail-safe applications" of this Manual must be carefully observed.
If parameters for the fail-safe functions are changed, then a new acceptance test must be
carried-out and included as acceptance log.
The template for the acceptance log is provided in printed form as example or
recommendation in this Operating Instructions.

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Contents of a complete acceptance test

Documentation
Documentation of the machine including the fail-safe functions.
● Machine description and overview/block diagram
● Fail-safe functions for each drive
● Description of the fail-safe devices/equipment.
Function test
Checking the individual fail-safe functions that are used.
● "Safe Torque Off" (STO)
● "Safe Stop 1" (SS1)
● "Safely-Limited Speed" (SLS)
● "Safe Brake Control" (SBC).
Completing the log
Document/log the commissioning phase and sign.
● Check the parameters of the fail-safe functions
● Document/log the checksums
● Provide proof that data has been backed-up/archived
● Sign.
Attachment
Measuring traces/plots associated with the function test.
● Alarm logs
● Trace plots.

Note
A form for an acceptance log is attached in the appendix of the operating instructions.

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5.9 Commissioning with PROFIBUS DP

5.9 Commissioning with PROFIBUS DP

5.9.1 PROFIdrive Profile

User data structure defined in PROFIdrive Profile 4.0

The SINAMICS G120 range of inverters can be controlled through the cyclical
PROFIBUS DP channel. The structure of user data for the cyclical/acyclical channel is
defined in the PROFIdrive Profile, version 4.0.
The PROFIdrive Profile defines for the inverters, the user data structure with which a master
can access the inverter slaves using the cyclical data communication method.

5.9.2 Using the PROFIBUS DP interface

Description
Prior to using the PROFIBUS DP interface, the address of the node (inverter) must be set.

Setting the PROFIBUS DP address

There are two methods for setting the PROFIBUS DP address:
● Using the seven DIP-switches on the Control Unit or
● Using parameter "P0918".

Caution
The inverter 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. The restart must be initiated by switching the power off and then on
again, irrespective of whether the interface is supplied from the inverter mains supply or
its own, separate 24 V connection.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 5-77
Commissioning (software)
5.9 Commissioning with PROFIBUS DP

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Figure 5-13 PROFIBUS DP address DIP-switches

The PROFIBUS DP address can be set between 1 and 125, as shown in the table below.

Table 5-19 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

Some "addresses" have a specific purpose, as shown in the table below:

Table 5-20 PROFIBUS DP address

DIP switch Meaning

settings
0 PROFIBUS DP address is determined by P0918
1 … 125 Valid PROFIBUS DP address
126, 127 Invalid PROFIBUS DP address

Control Units CU240S

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5.9 Commissioning with PROFIBUS DP

PROFIBUS DP parameters
The following parameters must be set to start-up the PROFIBUS DP interface:

Table 5-21 PROFIBUS DP parameters

Parameter Content
P0918 PROFIBUS address
P0700 Fast selection command source
P0922 Selects the PROFIBUS telegram standard
P1000 Fast selection frequency setpoint
P2038 Selects the communications profile
P2042 Selects if native ident number or NAMUR ident number is send to the PLC
r2050 Process data setpoint source (BICO)
P2051 Process data actual values (BICO)
P2041 Communication board functions
P2040 Process data telegram failure time
P0927 Modification source for parameters
r2054 Communication board diagnostics

P0918 PROFIBUS Address

● If address 0 is set on the DIP-switches of the Control Unit (default setting), then the
PROFIBUS DP address can be changed in parameter P0918. Valid settings are 1 to 125
(default = 3).
● Once a valid PROFIBUS DP address has been set on the DIP-switches, parameter
P0918 can no longer be changed. In this case, the parameter displays the
PROFIBUS DP address as set on the DIP-switches.
P0700 and P1000 Fast selection
● The control word and setpoint sources can be selected quickly in parameters P0700
(select command source) and P1000 (select frequency setpoint) respectively.
r2050 and P2051 BICO
● Much greater flexibility is afforded by the interconnection of process data using
binectors/connectors.
● Detailed connection of setpoints and actual values to and from the PROFIBUS DP
interface is parameterized in r2050 and P2051.
● The following table shows the parameters specific to the PROFIBUS DP interface relating
to the connection of process data:

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 5-79
Commissioning (software)
5.9 Commissioning with PROFIBUS DP

Table 5-22 Parameters for flexible interconnection of process data

Telegram PZD1 PZD2 PZD3 PZD4

STW/ZSW HSW/HIW
Link values for setpoints master to inverter r2050.00 r2050.01 r2050.02 r2050.03
Link parameters for actual values inverter to P2051.00 P2051.01 P2051.02 P2051.03
master

Note
r2050 also acts as a display parameter through which the setpoints received by the
PROFIBUS DP interface can be checked.

P2041 PROFIBUS DP functions

A number of advanced property settings for the PROFIBUS DP interface can be
accomplished using the indexed parameter P2041.
For most applications, however, the defaults values are adequate (value = 0). The following
table shows the property setting options.

Table 5-23 PROFIBUS DP functions

Parameter Meaning Value range

P2041.01 OP parameter in EEPROM: 0: Permanent (EEPROM)
Modifications to parameter settings 1: Volatile (RAM)
via SIMATIC HMI are stored
permanently in the EEPROM or as
volatile data in the RAM.
P2041.03 Select displayed diagnostics 0: Standard diagnostics
screen. >0: Special diagnostics (for SIEMENS internal use
only)

Caution
The watchdog function should not be deactivated! If the monitoring function is deactivated
and the PROFIBUS DP interface fails, the inverter will not recognize a fault condition and
continue to operate even if a fault condition exists.

Control Units CU240S

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 Commissioning (software)
5.9 Commissioning with PROFIBUS DP

Process data monitoring

Two parameters determine how process data are monitored:
● watchdog function on the PROFIBUS DP interface (standard slave function according to
PROFIBUS)
The watchdog function on the PROFIBUS DP interface is normally activated. It can be
deactivated by means of the PROFIBUS master configuring tool.
● Monitoring of the telegram failure time in the converter with parameter P2040

P2040 Telegram failure time

Parameter P2040 defines the time after which a fault will be generated (F0070) if no
telegram is received through the PROFIBUS DP interface.
● P2040 = 0 means: No monitoring
● P2040 > 0 means: The time in milliseconds after which a fault condition will be generated
if a setpoint telegram has not been received.
The fault conditions (F0070) is activated if no new setpoints are received by the
PROFIBUS DP interface within the telegram failure period.

Caution
Shutdown on faults can only take place if both monitoring functions are activated!

When the PROFIBUS DP interface is in operation, parameter P2040 should also be set to a
value of > 0. The process data monitoring function is thus activated/deactivated solely using
the PROFIBUS watchdog function. The monitoring time then corresponds to the watchdog
time setting plus the time set in P2040.

Note
Process data whose complete control word (PZD1) is set to zero are not transferred from the
PROFIBUS DP interface to the inverter.
Result: Alarm A0703 and possibly fault F0070.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 5-81
Commissioning (software)
5.9 Commissioning with PROFIBUS DP

P0927 Modification source for parameters

This parameter defines the interface through which parameters can be modified.

Bit Description Index

0 PROFIBUS DP 0: No 1: Yes
1 BOP 0: No 1: Yes
2 PC-Inverter Kit 0: No 1: Yes
3 RS485 0: No 1: Yes
The default setting for all bits is 1, i.e. parameters can be modified from all sources.

5.9.3 Data structures within PROFIdrive Profile

User data structure defined in PROFIdrive Profile 4.0

The SINAMICS G120 range of inverters can be controlled through the cyclical
PROFIBUS DP channel. The structure of user data for the cyclical/acyclical channel is
defined in the PROFIdrive Profile, version 4.0.
The PROFIdrive Profile defines for the inverters, the user data structure with which a master
can access the inverter slaves using the cyclical/acyclical data communication method.

Extended configuration for the SINAMICS G120

Up to 6 process data words (PZD), with a different number of setpoints and actual values if
desired, can be configured on the SINAMICS G120. They are combined to standard and
manufacturer-specific telegrams.

Telegrams
The selection of a telegram via P0922 determines on the drive unit side which process data
is transferred between master and slave.
From the perspective of the slave, the received process data comprises the receive words
and the process data to be sent the send words.
The receive and send words comprise the following elements:
● Receive words: Control words or setpoints
● Send words: Status words or actual values

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5.9 Commissioning with PROFIBUS DP

Used telegram types

The following telegrams can be set via parameter P0922:
Standard telegrams
The standard telegrams are structured in accordance with the PROFIdrive Profile. The
internal process data links are set up automatically in accordance with the telegram number
setting.
● Telegram 1 Speed control, 2 words
● Telegram 20 Speed control, VIK/NAMUR
Manufacturer-specific telegrams
The manufacturer-specific telegrams are structured in accordance with internal company
specifications. The internal process data links are set up automatically in accordance with
the telegram number setting.
● Telegram 350 Speed control, 4 words
● Telegram 352 Speed control, PCS7
Device-specific telegrams
The send and receive telegrams can be configured as required by using BICO technology to
interconnect the send and receive process data.
● Telegram 999 Free interconnection via BICO (up to 6 dat words)

5.9.4 Standard Telegram structure

BICO connection
When a telegram is selected, the corresponding BICO connection parameters will be fixed
and cannot be changed (except P0701 and the following digital inputs). If P0922 = 999, it
keeps the actual BICO connection parameters but now BICO parameters can be changed.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 5-83
Commissioning (software)
5.9 Commissioning with PROFIBUS DP

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Figure 5-14 Standard telegrams with different settings of P0922

5.9.5 VIK/NAMUR Telegram structure

Description

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Figure 5-15 Telegram structure VIK/NAMUR

Control Units CU240S

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5.9 Commissioning with PROFIBUS DP

If VIK/NAMUR telegram is selected with P0922 = 20, the parameter P2038 "Selection of
actual profile" will be set to VIK/NAMUR automatically.
It is also necessary to set the ident number (GSD) via parameter P2042:
● SIMATIC Object Manager (Slave-OM)
For drives configured with SIMATIC Object Manager (Slave-OM) parameter P2042 has to
be set to 0 (default).
● VIK/NAMUR GSD (Device Data File)
For all other configurations the setting of parameter P2042 must be changed to 1
(NAMUR). That means that the VIK/NAMUR ID of the PROFIBUS Nutzerorganisation
(PNO) will be send to the PLC.

Note
If changing PROFIBUS standard telegrams to VIK/NAMUR telegram or back
(parameters: P0922, P2038 and P2042) the drive ID is changed. A power cycle is
necessary for the Control Unit CU240S to take the changed drive ID effective.
To change back from VIK/NAMUR to Standard telegrams it is necessary to set
P0922 = 999 (Free BICO connection) and then reset P2038 and P2042 to PROFIdrive
Profile. If P0922 = 999, it keeps the actual BICO connection parameters but now BICO
parameters can be changed.

5.9.6 PROFIsafe telegram structure

Description
The fail-safe functions can be triggered via the fail-safe digital inputs FDI0 and FDI1 or via
PROFIsafe signals (see P9603 and 9803).
To use PROFIsafe for triggering the fail-safe functions the G120 GSD file must be installed
in the control system e.g. SIMATIC S7.
Input and output address, 6 byte each (input and otuput address are identical)

• Byte 0 (process data 0), Bit 0: STO 0 = selected 1 not selected

• Byte 0 (process data 0), Bit 1: SS1 0 = selected 1 not selected
• Byte 1 (process data 1), Bit 0: SLS 0 = selected 1 not selected

Table 5-24 Intput addresses for PROFIsafe signals

Address Function
1 E 0.0 STO bit from inverter
2 E 0.1 SS1 bit from inverter
…

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 5-85
Commissioning (software)
5.9 Commissioning with PROFIBUS DP

Address Function
9 E 1.0 SLS bit from inverter

Table 5-25 Output addresses for PROFIsafe signals

Address Function
1 A 0.0 STO bit to inverter
2 A 0.1 SS1 bit to inverter
…
9 A 1.0 SLS to from inverter

5.9.7 Switch over behavior of Communication telegram

Overview

Table 5-26 Switch over behavior of telegram structures, Part 1

P0922 = 1 → 20 1 → 350 1 → 352 1 → 999

if if if if if if if if
P0700 ≠ 6 P0700 = 6 P0700 ≠ 6 P0700 = 6 P0700 ≠ 6 P0700 = 6 P0700 ≠ 6 P0700 = 6
P0820 = 2032.15 2091.15 unchanged 2091.4 unchanged unchanged unchanged unchanged
P0821 = unchanged unchanged unchanged 2091.5 unchanged unchanged unchanged unchanged
P1035 = 19.13 19.13 unchanged 2090.13 unchanged 2090.13 unchanged unchanged
P1036 = 19.14 19.14 unchanged 2090.14 unchanged 2090.14 unchanged unchanged

Table 5-27 Switch over behavior of telegram structures, Part 2

P0922 = 20 → 1 20 → 350 20 → 352 20 → 999

if if if if if if if if
P0700 ≠ 6 P0700 = 6 P0700 ≠ 6 P0700 = 6 P0700 ≠ 6 P0700 = 6 P0700 ≠ 6 P0700 = 6
P0820 = 0.0 0.0 unchanged 2091.4 0.0 0.0 unchanged unchanged
P0821 = unchanged unchanged unchanged 2091.5 unchanged unchanged unchanged unchanged
P1035 = unchanged 2090.13 unchanged 2090.13 unchanged 2090.13 unchanged unchanged
P1036 = unchanged 2090.14 unchanged 2090.14 unchanged 2090.14 unchanged unchanged

Control Units CU240S

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 Commissioning (software)
5.9 Commissioning with PROFIBUS DP

Table 5-28 Switch over behavior of telegram structures, Part 3

P0922 = 350 → 1 350 → 20 350 → 352 350 → 999

if if if if if if if if
P0700 ≠ 6 P0700 = 6 P0700 ≠ 6 P0700 = 6 P0700 ≠ 6 P0700 = 6 P0700 ≠ 6 P0700 = 6
P0820 = 0.0 0.0 2032.15 2091.15 0.0 0.0 unchanged unchanged
P0821 = 0.0 0.0 0.0 0.0 0.0 0.0 unchanged unchanged
P1035 = unchanged 2090.13 19.13 19.13 unchanged 2090.13 unchanged unchanged
P1036 = unchanged 2090.14 19.14 19.14 unchanged 2090.14 unchanged unchanged

Table 5-29 Switch over behavior of telegram structures, Part 4

P0922 = 352 → 1 352 → 20 352 → 350 352 → 999

if if if if if if if if
P0700 ≠ 6 P0700 = 6 P0700 ≠ 6 P0700 = 6 P0700 ≠ 6 P0700 = 6 P0700 ≠ 6 P0700 = 6
P0820 = 0.0 0.0 2032.15 2091.15 unchanged 2091.4 unchanged unchanged
P0821 = unchanged unchanged unchanged unchanged unchanged 2091.5 unchanged unchanged
P1035 = unchanged 2090.13 19.13 19.13 unchanged 2090.13 unchanged unchanged
P1036 = unchanged 2090.14 19.14 19.14 unchanged 2090.14 unchanged unchanged

Table 5-30 Switch over behavior of telegram structures, Part 5

P0922 = 999 → 1 999 → 20 999 → 350 999 → 352

if if if if if if if if
P0700 ≠ 6 P0700 = 6 P0700 ≠ 6 P0700 = 6 P0700 ≠ 6 P0700 = 6 P0700 ≠ 6 P0700 = 6
P0820 = 0.0 0.0 2032.15 2091.15 unchanged 2091.4 unchanged unchanged
P0821 = unchanged unchanged unchanged unchanged unchanged 2091.5 unchanged unchanged
P1035 = unchanged 2090.13 19.13 19.13 unchanged 2090.13 unchanged 2090.13
P1036 = unchanged 2090.14 19.14 19.14 unchanged 2090.14 unchanged 2090.14

5.9.8 Control and status words

Description
The control and status words comply with the specifications for PROFIdrive Profile, version
4.0 for "Closed-loop speed control mode".

Control word 1 (STW1)

Control word 1 (bits 0 … 10 as per PROFIdrive Profile and VIK/NAMUR, bits 11 … 15
specific to SINAMICS G120).

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 5-87
Commissioning (software)
5.9 Commissioning with PROFIBUS DP

Table 5-31 Assignment control word 1

Bit Val. Meaning P0922 = P0922 = 1 /

comment 20 350 / 352
(VIK/ (PROFI
NAMUR) drive Profile)
0 0 OFF1 P0840 = P0840 =
Shutdown, deceleration along RFG ramp, pulse disable when f < fmin. 2090:0 2090:0
1 ON
Sets the inverter to the "Ready to run" state, direction of rotation must be
defined via bit 11.
1 0 Coast Stop (OFF2) P0844 = P0844 =
Instantaneous pulse disable, drive coasts to a standstill 2090:1 2090:1
1 No Coast Stop
All Coast Stop (OFF2) commands are withdrawn.
2 0 Quick Stop (OFF3) P0848 = P0848 =
Rapid stop: Shutdown at fastest possible acceleration rate. 2090:2 2090:2
1 No Quick Stop
All Quick Stop (OFF3) commands are withdrawn.
3 0 Disable Operation P0852 = P0852 =
Closed-loop control and inverter pulses are disabled 2090:3 2090:3
1 Enable Operation
Closed-loop control and inverter pulses are enabled
4 0 Reset Ramp Generator P1140 = P1140 =
Output of RFG is set to 0 (fastest possible braking operation), inverter 2090:4 2090:4
remains in the ON state.
1 Enable Ramp Generator
5 0 Freeze Ramp Generator P1141 = P1141 =
Setpoint currently supplied by the RFG is "frozen". 2090:5 2090:5
1 Unfreeze Ramp Generator
6 0 Disable Setpoint P1142 = P1142 =
Value selected at the RFG input is set to 0. 2090:6 2090:6
1 Enable Setpoint
Value selected at the RFG input is activated.
7 1 Fault Acknowledge P1024 = P1024 =
Fault is acknowledged with a positive edge, inverter then switches to 2090:7 2090:7
"starting lockout" state.
8 0 JOG 1 OFF P1055 = P1055 =
Drive brakes as quickly as possible. 2090:8 2090:8
1 JOG 1 ON
The drive runs up as quickly as possible to jogging setpoint (direction of
rotation: CW).
9 0 JOG 2 OFF P1056 = P1056 =
Drive brakes as quickly as possible. 2090:9 2090:9
1 JOG 2 ON
The drive runs up as quickly as possible to jogging setpoint (direction of
rotation: CCW).
10 0 No PLCControl ---- ----
Process data not valid, expect Sign-Of-Life.
1 PLC Control
Control via interface, process data valid.

Control Units CU240S

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5.9 Commissioning with PROFIBUS DP

Bit Val. Meaning P0922 = P0922 = 1 /

comment 20 350 / 352
(VIK/ (PROFI
NAMUR) drive Profile)
11 0 No Setpoint Inversion P1113 =
Motor rotates CW in response to positive setpoint. 2090:11
1 Setpoint Inversion
Motor rotates CCW in response to positive setpoint.
12 Not used Not used Not used
13 1 Motor potentiometer UP Not used P1035 =
2090:13
14 1 Motor potentiometer DOWN P1036 =
2090:14
15 1 Depends on the protocol DDS1: CDS1:
On the SINAMICS G120 it is possible, using the function local/remote P0820 = P0810 =
control, to change between the command data set (CDS) 0 and 1 of the 2091.15 2090:15*
control word 1 bit 15. This results in a switching of the command data
sets. The command data set 0 is active in local operation and the
command data set 1 for remote operation. Now in both command data
sets the application-specific parameters for the command and target
value sources can be set.
*Note: In PROFIdrive Profile P0810 = 2090:15 must be set manually.

An example
In the remote control operating mode the commands and target values come from a superior
control system to the inverter by means of a PROFIBUS. By switching to local operation, the
command and target value source is switched and operation is now performed locally on the
system by means of digital inputs and the analog target values.
Local operation = Command data set 0: In this case the command code of the terminal strip
P0700 Index 0 = 2 and the frequency target value is the analog target value P1000
Index 0 = 2.
Remote operation = Command data set 1: In this case the command code corresponds with
the control word (word 0) received from the PROFIBUS P0700 Index 1 = 6 and the
frequency target value corresponds with the control word 1 received from the PROFIBUS
P1000 Index 0 = 6.

Control Units CU240S

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5.9 Commissioning with PROFIBUS DP

Default assignment control word 2 (STW2)

The control word 2 is assigned as a default as follows. This can be changed by using BICO.

Table 5-32 Assignment control word 2 (for VIK/NAMUR not defined)

Bit Value Meaning P0922 = 1 P0922 = 350 P0922 = 352

0 1 Fixed frequency selection Bit 0 P1020 depends on P070x = P1020 P1020 depends on P070x
1 1 Fixed frequency selection Bit 1 P1021 depends on P070x = P1021 P1021 depends on P070x
2 1 Fixed frequency selection Bit 2 P1022 depends on P070x = P1022 P1022 depends on P070x
3 1 Fixed frequency selection Bit 3 P1023 depends on P070x = P1023 P1023 depends on P070x
4 – Not used -- -- --
5 – Not used -- -- --
6 – Not used -- -- --
7 – Not used -- -- --
8 1 Enable Technology Controller 0.0 = P2200 0.0
9 1 Enable DC Brake 0.0 = P1230 0.0
10 – Not used -- -- --
11 1 Enable Droop Speed Controller Enable Droop Enable Droop Enable Droop
12 1 Torque Control 0.0 = P1501 0.0
0 Speed Control
13 0 External Fault 1 1.0 = P2106 1.0
14 – Not used -- -- --
15 – Not used -- -- --

Status word 1 (ZSW1)

Status word 1 (bits 0 to 10 as per PROFIdrive Profile and VIK/NAMUR, bits 11 to 15 specific
to SINAMICS G120).

Table 5-33 Bit assignments status word 1 (for all PROFIdrive and VIK/NAMUR telegrams)

Bit Value Meaning Remarks

0 1 Ready to switch on Power supply is switched on, electronics initialized, pulses
disabled.
0 Not ready to switch on --
1 1 Ready to operate Inverter is switched on (ON command is applied), no fault is
active, inverter can start when "Enable operation" command
is issued. See control word 1, bit 0.
0 Not ready to operate --
2 1 Operation enabled Drive follows setpoint. See control word 1, bit 3.
0 Operation disabled --
3 1 Fault present Drive has faulted. Drive is faulty and thus inoperative,
switches to starting lockout state after successful correction
and acknowledgement of fault.
0 No fault --
4 1 Coast Stop not activated --

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Bit Value Meaning Remarks

0 Coast Stop activated Coast Stop (OFF 2) command is present.
5 1 Quick Stop not activated --
0 Quick Stop activated Quick Stop (OFF 3) command is present.
6 1 Switching on inhibited The drive goes only again in the "Switched On" condition
with "No Coast Stop AND No Quick Stop" followed by "ON".
0 Switching on not inhibit --
7 1 Warning present Drive still works; warning in the service/maintenance para-
meter; no acknowledgement, see alarm parameter r2110.
0 No warning There is no warning or the warning has disappeared again.
8 1 Speed error within tolerance range Setpoint/actual value deviation within tolerance range.
0 Speed error out of tolerance range --
9 1 Master control requested The automation system is requested to assume control.
0 No control requested The master is not currently the master control.
10 1 Maximum frequency reached or Inverter output frequency is higher or equal to the maximum
exceeded frequency.
0 Maximum frequency not reached --
11 1 -- --
0 Warning: Motor at current/torque limit --
12 1 Motor holding brake active Signal can be used to control a holding brake.
0 -- --
13 1 -- Motor data indicate overload condition.
0 Motor overload --
14 1 CW rotation --
0 CCW rotation --
15 1 -- --
0 Inverter overload e.g. current or temperature.

Control Units CU240S

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Commissioning (software)
5.9 Commissioning with PROFIBUS DP

Status word 2 (ZSW2)

Status word 2 has the following default assignment: This can be modified using BICO.

Table 5-34 Assignment status word 2 (for VIK/NAMUR not defined)

Bit Value Meaning Description

0 1 DC Braking Active DC current brake active
1 1 n_act < P2167 Drive inverter frequency < Shutdown limit
2 1 n_act ≧ P1080 Actual frequency > min. frequency
3 1 i_act ≧ P2170 Current ≥ Limit
4 1 n_act > P2155 Actual frequency > Reference frequency
5 1 n_act ≦ P2155 Actual frequency < Reference frequency
6 1 Speed Setpoint Reached Actual frequency ≥ Setpoint
7 1 DC Link Voltage < P2172 Voltage < Threshold value
8 1 DC Link Voltage ≧ P2172 Voltage > Threshold value
9 1 Speed Ramp Finished --
10 1 Techn. Controller Output ≦ P2292 PI frequency < Threshold value
11 1 Techn. Controller Output > P2291 PI saturation
12 1 Vdc_max Controller --
13 1 Kinetic Buffering and Flexible Response --
14 1 Not used --
15 1 Not used --

5.9.9 Acyclic data transmission

Extended PROFIBUS DP functionality (DPV1)

The PROFIBUS DP extensions DPV1 include the definition of an acyclic data exchange
which can take place in parallel to cyclical data transmissions.
Acyclic data transfer mode allows:
● Large quantities of user data (up to 240 bytes) to be exchanged
● Simultaneous accessing by other PROFIBUS masters (class 2 master, e.g. start-up tool).

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5.9 Commissioning with PROFIBUS DP

Conversion of extended PROFIBUS DP functionality

The different masters, or different modes of data exchange, are represented by appropriate
channels in the SINAMICS G120 range of inverters:
● Acyclical data exchange with the same class 1 master use of DPV1 functions READ and
WRITE. The content of the transferred data block (DS) corresponds in this case to the
structure of the acyclical parameter channel according to PROFIdrive Profile, version 4.0
(http://www.profibus.com/organization.html) (with data block 47 (DS47)).
● Acyclical data exchange using a SIEMENS start-up tool (class 2 master) (e.g.
STARTER). The start-up tool can acyclically access parameter and process data in the
inverter.
● Acyclical data exchange with a SIMATIC HMI (second class 2 master). The SIMATIC HMI
can acyclically access parameters in the inverter.
● Instead of a SIEMENS start-up tool or SIMATIC HMI, an external master (class 2 master)
as defined in the acyclical parameter channel according to PROFIdrive Profile version 4.0
(with DS47) can access the inverter.

Properties of the DPV1 parameter channel

● One 16-bit address each for parameter number and subindex.
● Concurrent access by several PROFIBUS masters (class 2 master, e.g. commissioning
tool).
● Transfer of different parameters in one access (multiple parameter request).
● Transfer of complete arrays or part of an array possible.
● Only one parameter request is processed at a time (no pipelining).
● A parameter request/response must fit into a data set (max. 240 bytes).
● The task or response header are user data.

Structure of parameter request and parameter response

A parameter request consists of three segments:
● Request header
ID for the request and number of parameters which are accessed.
● Parameter address
Addressing of a parameter. If several parameters are accessed, there are
correspondingly many parameter addresses. The parameter address appears only in the
request, not in the response.
● Parameter value
Per addressed parameter, there is a segment for the parameter values. Depending on
the request ID, parameter values appear only either in the request or in the reply.

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Table 5-35 Parameter request

Word
Byte Byte
Request header Request Reference Request ID
Drive object ID No. of Parameters
1st Parameter Address Attribute No. of elements
Parameter Number (PNU)
Subindex
…
nth Parameter Address Attribute No. of elements
Parameter Number (PNU)
Subindex
1stParameter Value(s) Format No. of Values
(only for request Values
"Change parameter")
…
…
nth Parameter Value(s) Format No. of Values
Values
…

Table 5-36 Parameter response

Word
Byte Byte
Response header Request Reference mirrored Response ID
Drive object ID mirrored No. of Parameters
1st Parameter Value(s) Format No. of Values
(only after request "Request") Values or Error Values
…
…
nth Parameter Value(s) Format No. of Values
Values or Error Values
…

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Description of fields in DPV1 parameter request and response

Table 5-37 Description of fields in parameter request

Field Data type Values Note

Request Unsigned8 0x01 … 0xFF
reference Unique identification of the request/response pair for the master. The master
changes the request reference with each new request. The slave mirrors the
request reference in its response.
Request ID Unsigned8 0x01 Read request
0x02 Write request
Specifies the type of request.
In the case of a write request, the changes are made in a volatile memory (RAM).
A save operation is needed in order to transfer the data to the non-volatile
memory (P0971).
Drive object ID Unsigned8 0x00 … 0xFF Number
Setting for the drive object number with a drive unit with more than one drive
object. Different drive objects with separate parameter number ranges can be
accessed over the same DPV1 connection.
No. of Unsigned8 0x01 … 0x27 No. 1 … 39
Parameters Limited by DPV1 telegram length
Defines the number of adjoining areas for the parameter address and/or
parameter value for multi-parameter requests.
The number of parameters = 1 for single requests.
Attribute Unsigned8 0x10 Value
0x20 Description
0x30 Text (not implemented)
Type of parameter element accessed.
No. of Elements Unsigned8 0x00 Special function
0x01 … 0x75 No. 1 … 117
Limited by DPV1 telegram length
Number of array elements accessed.
Parameter Unsigned16 0x0001 … 0xF No. 1 … 65535
number FFF
Addresses the parameter to be accessed.
Subindex Unsigned16 0x0000 … 0xF No. 0 … 65535
FFF
Addresses the first array element of the parameter to be accessed.
Format Unsigned8 0x02 Data type Integer 8
0x03 Data type Integer 16
0x04 Data type Integer 32
0x05 Data type Unsigned 8
0x06 Data type Unsigned 16
0x07 Data type Unsigned 32
0x08 Data type Floating Point
Other values See PROFIdrive Profile

0x40 Zero (without values as a positive

subresponse to a write request)
0x41 Byte
0x42 Word
0x43 Double word
0x44 Error

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Field Data type Values Note

The format and number specify the adjoining space containing values in the
telegram.
Data types in conformity with PROFIdrive Profile shall be preferred for write
access. Bytes, words and double words are also possible as a substitute.
No. of Values Unsigned8 0x00 … 0xEA No. 0 … 234
Limited by DPV1 telegram length
Specifies the number of subsequent values.
Values Unsigned16 0x0000 … 0x0
0FF
The values of the parameter for read or write access.
If the values make up an odd number of bytes, a zero byte is appended. This
ensures the integrity of the word structure of the telegram.

Table 5-38 Description of fields in parameter response

Field Data type Values Note

Request See Table above
reference
Response ID Unsigned8 0x01 Read request Request positive, status ok
0x02 (+) Request negative, fault status
0x81 Write request
0x82 (+)
Read request
(–)
Write request
(–)
Mirrors the request identifier and specifies whether request execution was
positive or negative.
Negative means:
Cannot execute part or all of request.
The error values are transferred instead of the values for each subresponse.
Drive object ID See Table above
No. of See Table above
Parameters
Format See Table above
No. of Values See Table above
Values See Table above
Error Values Unsigned16 0x0000 … 0x0 Meaning of the error values see next Table
0FF
The error values in the event of a negative response.
If the values make up an odd number of bytes, a zero byte is appended. This
ensures the integrity of the word structure of the telegram.

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Note
Drive ES SIMATIC provides function blocks for parameter write/read tasks within standard
block libraries and some examples.

Error values in DPV1 parameter responses

Table 5-39 Error values in DPV1 parameter responses

Error Meaning Note Extra info

value
0x00 Illegal parameter number Access to a parameter which does not –
exist.
0x01 Parameter value cannot be changed Modification access to a parameter Subindex
value which cannot be changed.
0x02 Lower or upper value limit exceeded Modification access with value outside Subindex
value limits.
0x03 Invalid subindex Access to a subindex which does not Subindex
exist.
0x04 No array Access with subindex to an unindexed –
parameter.
0x05 Wrong data type Modification access with a value which –
does not match the data type of the
parameter.
0x06 Illegal set operation (only reset Modification access with a value not Subindex
allowed) equal to 0 in a case where this is not
allowed.
0x07 Description element cannot be Modification access to a description Subindex
changed element which cannot be changed.
0x09 No description data Access to a description which does not –
exist (the parameter value exists).
0x0B No operating priority Modification access with no operating –
priority.
0x0F No text array exists Access to a text array which does not –
exist (the parameter value exists).
0x11 Request cannot be executed due to Access is not possible temporarily for –
operating status unspecified reasons.
0x14 Illegal value Modification access with a value which Subindex
is within the limits but which is illegal
for other permanent reasons
(parameter with defined individual
values).
0x15 Response too long The length of the present response –
exceeds the maximum transfer length.

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Error Meaning Note Extra info

value
0x16 Illegal parameter address Illegal or unsupported value for –
attribute, number of elements,
parameter number, subindex or a
combination of these.
0x17 Illegal format Write request: illegal or unsupported –
parameter data format.
0x18 No. of values inconsistent Write request: a mismatch exists –
between the number of values in the
parameter data and the number of
elements in the parameter address.
0x19 Drive object does not exist Access to a drive object which does –
not exist.
0x20 Parameter text element cannot be Change access to a parameter text Subindex
changed element that cannot be changed.

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5.9.10 Configuration Example with SIMATIC S7

Installing a G120 GSD file

The inverter can be integrated into a higher level control device, e.g. SIMATIC S7 via the
GSD file. It can be downloaded from the internet via:
http://support.automation.siemens.com/WW/view/de/23450835
The GSD must be installed in the engineering software of the higher level control device.
The following example shows how to install the GSD in HW Config of SIMATIC S7.

Figure 5-16 Installing the G120 GSD in HW config SIMATIC S7

Install the *.GS* file in the desired language (english, french, german, italian or spanish) from
the folder where you have stored these data.
The following figure shows how to integrate an inverter with integrated fail-safe functions and
a SIEMENS standard telegramm in a SIMATIC S7.
The inverter gives the possibility to work with different kind of telegrams. The selection of the
telegram is made by the parameter P0922 during drive commissioning. The received
telegram is in r2050[8] and transmit telegram is decided by parameter P2051[8].

Note
Take care that the PROFIsafe Module is installed in slot 1. In the following slot a SIEMENS
telegram or a standard telegram can be installed.

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Figure 5-17 G120 inverter with fail-safe functions and a standard protocol in HW config of SIMATIC
S7

PROFIsafe Parameters
The PROFIsafe parameters are shown in the following dialog box (to be opened eg. via left
mouse double click on PROFIsafe module).
Only the parameters
● F_Dest_Add: PROFIsafe address
● F_WD_Time: control time for the fail-safe functions
can be changed.

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Figure 5-18 Dialog mask for fail-safe functions

Caution
F_Dest_Add
The PROFIsafe address is per default identical to the PROFIBUS address. Due to safety
reasons it must be changed to a different value. It needs also to be changed in P9810 of the
inverter.
F_WD_Time
In conjunction with the sync/freeze function, the watchdog-time should be increased.

A more detailed desctiption can be downloaded from

http://support.automation.siemens.com/WW/view/en/23646766.

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5.9.10.1 Read Parameters

Requirements
● The PROFIBUS master has been commissioned and is fully operational.
● PROFIBUS communication between master and slave is operational.
● The master can read and write data sets in conformance with PROFIBUS DPV1.

Task description
Following the occurrence of at least one fault (ZSW1.3 = 1) the first 8 active fault codes must
be read from the fault buffer r0947[0] … r0947[7]. The accompanied faults values of the fault
code are important for the user. These must be read from parameter r0949 [0] ...r0949[7].
The request is to be handled using a request and response data block.

Procedure
1. Create a request data block e.g. DB1 to read the parameters

Figure 5-19 Request data block e.g. DB1 to read the parameters

Table 5-40 Parameter request

Request header Request_reference = 0x01 Request_ID = 0x01

Drive_object_ID = 0x00 No_of_parameters = 0x02
Parameter Address_01 Attribute_parameter_01 = 0x10 No_of_elements_01 = 0x08
parameter_number_01 (PNU) = 03B3 (= 947 dec, P0947)
Subindex_01 = 0x00
Parameter Address_02 Attribute_parameter_02 = 0x10 No_of_elements_02 = 0x08
parameter_number_02 (PNU) = 03B5 (= 949 dec, P0949)
Subindex_02 = 0x00

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Information about the parameter request:

● Request_reference:
The value is selected at random from the valid value range. The request reference
establishes the relationship between request and response.
● Request_ID:
0x01 --> This identifier is required for a read request.
● Drive_object_ID:
0x00 -> Device-Representative.
● No_of_parameters:
0x02 --> Two parameters are read.
● Attribute_parameter_01:
0x10 --> The parameter values are read.
● No_of_elements_01:
0x08 --> The current fault incident with 8 faults is to be read.
● Parameter_number_01:
03B3 --> P0947 (last fault code) is read.
● Subindex_01:
0x00 --> Read access starts at index 0
● Attribute_parameter_02:
0x10 --> The parameter values are read.
● No_of_elements_02:
0x08 --> The current fault incident with 8 faults is to be read.
● Parameter_number_02:
03B5 --> P0949 (last fault code) is read.
● Subindex_02:
0x00 --> Read access starts at index 0.
1. Create a response data block e.g. DB2 for the response

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Figure 5-20 Response data block e.g. DB2 for the response

Table 5-41 Parameter response

Response header Request_reference mirror = 0x01 Response_ID = 0x01

Drive_object_ID_mirrored = 0x00 No_of_parameters = 0x02
Parameter Value(s) Format_parameter_1 = 0x06 No_of_values_parameter_1 = 0x08
error_code_01 = 0x054B (= 1355 dec, F1355)
error_code_02 = 0x0000
…
error_code_08 = 0x0000
Parameter Value(s) Format_parameter_2 = 0x06 No_of_values_parameter_2 = 0x08
error_value_01 = 0x054B (= 1355 dec, F1355)
error_value_02 = 0x00
…
error_value_08 = 0x00

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Information about the parameter response:

● Request_reference_mirror:
This response belongs to the request with request reference 0x01.
● Response_ID:
0x01 --> Read request positive, values stored as 1st value.
● Drive_object_ID_mirrored:
The values correspond to the values from the request.
● No_of_parameters:
The values correspond to the values from the request.
● Format_parameter_1:
0x06 --> Parameter values are in Unsigned16 format.
● No_of_values_parameter_1:
0x08 --> 8 parameter values are available.
– 1. value … 8. value:
error_codes_01
…
error_codes_08
● Format_Parameter_2:
0x06 --> Parameter values are in Unsigned16 format.
● No. of values_Parameter_2:
0x08 --> 8 parameter values are available.
– 1. value … 8. value:
error_values_01
…
error_values_08.

1. For the acyclic communication in OB1 a read/write request must be send to the drive with
RD_REC (SFC 59) and WR_REC (SFC 58)

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Figure 5-21 Acyclic communication for request and response data block in OB1

5.9.10.2 Write Parameters

Requirements
● The PROFIBUS master has been commissioned and is fully operational.
● PROFIBUS communication between master and slave is operational.
● The master can read and write data sets in conformance with PROFIBUS DPV1.

Task description (multiple parameter request)

The maximum frequency (parameter P1082) shall change from 50 Hz (default value) to
100 Hz.

Procedure
1. Create a request data block e.g. DB1 to write the parameter

Figure 5-22 Request data block e.g. DB1 to write the parameter

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Information about the parameter request:

● Request_reference:
The value is selected at random from the valid value range. The request reference
establishes the relationship between request and response.
● Request_ID:
0x02 --> This identifier is required for a write request.
● Drive_object_ID:
0x00 -> Device-Representative (for G120 inverters = 0).
● No_of_parameters:
0x01 --> One parameter request.
● Attribute:
0x10 -> The parameter value are to be written.
● No_of_elements:
0x01 -> 1 array element is written.
● Parameter_number:
043A -> Parameter P1082 (max. frequency); 043A hex = 1082 dec.
● Subindex:
0x00 -> ID for the first array element.
● Format:
0x43 -> Floating Point data type (refer to the Parameter List).
● No_of_values:
0x01 -> One value is written to the parameter in the specified format.
● Value:
1.000000e+002 -> maximum frequency 100 Hz.
1. For the acyclic communication in OB1 a write request must be send to the drive with
WR_REC (SFC 58)

Figure 5-23 Acyclic communication in OB1

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5.10 Encoder Commissioning

5.10 Encoder Commissioning

Description

Warning
Before installing and commissioning, please read these safety instructions and warning
carefully and all the warning labels attached to the equipment. Make sure that the warning
labels are kept in a legible condition and replace missing or damaged labels.
This equipment contains dangerous voltages and controls potentially dangerous rotating
mechanical parts.
Non-Compliance with Warnings or failure to follow the instructions contained in this manual
can result in loss of life, severe personal injury or serious damage to property.
Only suitably qualified personnel should work on this equipment, and only after becoming
familiar with all safety notices and maintenance procedures contained in this manual.
The successful and safe operation of this equipment is dependent upon its proper handling,
storage, installation, operation and maintenance.
National safety regulations are also applicable.

The actions required to commission the encoder depend upon the type (HTL or TTL) that is
connected to the encoder interface. The following table gives an overview about the single
steps depending on the type of encoder.

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Procedure of encoder commissioning

To commission the Encoder, the following procedure should be performed:
Table 5-42 Commissioning the Encoder

Step Description TTL HTL

1. Ensure the Inverter is switched off. X X
2. Connect the Channel A wire from the encoder to terminal 70 (ENC AP) on the X X
Control Unit.
3. Connect the Channel A inverted wire from the encoder to terminal 71 (ENC X X
AN) on the Control Unit.
4. Connect the Channel B wire from the encoder to terminal 72 (ENC BP) on the X X
Control Unit.
5. Connect the Channel B inverted wire from the encoder to terminal 73 (ENC X X
BN) on the Control Unit.
6. Connect the Channel Z wire from the encoder to terminal 74 (ENC ZP) on the X X
Control Unit.
7. Connect the Channel Z inverted wire from the encoder to terminal 75 (ENC X X
ZN) on the Control Unit.
8. Connect the positive power cable to terminal 33 (ENC+ SUPPLY) on the X X
Control Unit.
9. Connect the negative power cable to terminal 28 (U0V) on the Control Unit. X X
10. Switch the general I/O DIP-switch 4 (5 V) to the ON position (TTL) X
11. Switch the general I/O DIP-switch 3 (24 V) to the ON position. (HTL) X
12. Check that all the connections have been made correctly and the DIP-switch X X
is in the correct position.
13. Switch the inverter ON. X X
14. The Encoder interface now requires to be parameterized. A flow chart that X X
shows the required parameters is given in the following section.

Note
The cable from the encoder to the Encoder Module should be one complete length.
TTL-encoder specific
If the encoder type is a TTL differential and a long cable length is required (>50 m), DIP
switches 5, 6, and 7 may be set to ON.
If the encoder type is a TTL single-ended encoder, there will be a three wires for the ‘A’, 'B'
and 'Z' Channels.
HTL-encoder specific
The terminating impedance which is selected using the DIP-switches must not be used in
conjunction with an HTL encoder.

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The encoder voltage is using the general I/O DIP switches 3 and 4.
The following table shows the possible settings:

Table 5-43 Encoder voltage settings

On

9(QFRGHU

9(QFRGHU

9(QFRGHU

9(QFRGHU
9(QFRGHU

9(QFRGHU

9(QFRGHU

9(QFRGHU
VXSSO\

VXSSO\

VXSSO\

VXSSO\

VXSSO\

VXSSO\

VXSSO\

VXSSO\
OFF

3 4 3 4 3 4 3 4

Encoder supply 0V 24 V 5V 24 V
voltage
Encoder type No encoder HTL encoder TTL encoder HTL encoder

Warning
DIP switches 3 and 4 in ON position provide a supply voltage of 24 V to the encoder.
Therefore it is not allowed to connect a TTL encoder to the inverter if both DIP switches, 3
and 4 are in ON position.

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5.10.1 Parameterizing the Encoder Interface

Encoder parameterization
To enable the Encoder to function correctly with the inverter, the parameters in the table
below, must be modified.

Table 5-44 Encoder parameters

Parameter Name
Comment
P0400[3] Encoder type
• 0: No encoder
• 2 or12: Quadrature encoder (channel A + B) –
the term "quadrature" means two periodic functions separated by a quarter cycle or 90 degrees
P0405 Encoder pulse types
Enables selection of various pulse types. Only bits 04 and 05 are used for the SINAMICS G120. See
parameter list.
P0408[3] Pulses per revolution
Specifies the number of encoder pulses per revolution. The manufacturer of the speed encoder
specifies this value. 360, 500 or 1024 are values that are generally used.
The encoder resolution (pulses per revolution p0408) which may be entered will be limited by the max.
pulse frequency of the encoder circuits (f_max = 300 kHz). The following equation calculates the
encoder frequency depending on the encoder resolution and the rotational speed (rpm). The encoder
frequency has to be less than the max. pulse frequency:
3[8PLQ
IPD[!I 

P0410 Reverses internal direction sense
Setting P0410 =1 can be used to reverse the encoder signals instead of changing ENC_A and ENC_B
wiring.
0: Encoder Normal Rotation
1: Encoder Reverse Rotation
P0491[3] Reaction on speed signal loss
Selects reaction on loss of speed signal. Settings:
0: Trip with OFF2
1: Alarm and change to SLVC

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Parameter Name
Comment
P0492[3] Allowed speed difference
This parameter defines the frequency threshold for the loss of the encoder signal (fault F0090). The
threshold is used both for low as well as also high frequencies.
1. Signal loss at high frequencies:
Fault F0090 is output if the actual frequency and the frequency difference between two sampling
periods (t_A) is greater than that specified in parameter p0492:
(actual frequency f_act > p0492 and f(t_A2) - f(t_A1) > p0492)
Note
A fixed delay time of 40 ms is stored in the frequency converter. Fault F0090 is only activated when
the encoder signal is lost at a high frequency after this delay time has expired.
2. Signal loss at low frequencies:
Fault F0090 is output if all of the conditions for case 1 or case 2 are simultaneously fulfilled:
Case 1
– actual frequency < p0492
– r0061 = 0 and the torque is limited
– r0061 = 0 with setpoint frequency f_set > 0 for a time > p0494
Case 2
- actual frequency < p0492
- f(t_A2) < p0492 and a fault is detected in channel B
Inter-dependency
This parameter is updated after the motor starting time p0345 has been changed or the speed was
optimized (p1960 = 1).
Caution
p0492 = 0 (no monitoring function):
With p0492 = 0, the loss of the encoder signal at high frequency as well as at a low frequency is de-
activated. As a result, the system does not monitor for the loss of the encoder signal.
If the encoder signal loss is de-activated and the fault occurs, then the closed-loop motor control can
become unstable
P0493[3] Speed difference
Allowed difference between encoder and observer.
P0494[3] Delay speed loss reaction
Used for low speed encoder loss detection.
If the motor shaft speed is less than the value in P0492 then encoder loss is detected using a low
speed encoder loss detection algorithm. This parameter selects the delay between loss of encoder at
low speed and reaction to the encoder loss. (Default = Calculated from inertia, Range from 0 to
64.000s).
Dependency: This parameter is updated when P0345 Motor start-up time is changed or when a speed-
loop optimization is performed (P1960 = 1).
Caution: When this delay is set to 0, then low speed encoder loss detection is disabled and low speed
encoder loss cannot be detected (high speed encoder loss detection will still operate if P0492 > 0). If
low speed encoder loss detection is disabled and encoder should be lost at low speed, then operation
of motor may become unstable.
P1300 Control Mode
21: Closed loop speed control
23: Closed loop torque control

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Table 5-45 Monitoring parameters

Parameter Name
Comment
r0061 CO: Rotor speed
Indicates the speed of the rotor. Used to check that the system is working correctly.
r0090 CO: Act. rotor angle
Indicates the current angle of the rotor. This function is not available on single input channel encoders.
r0403 CO/BO: Encoder status word
Displays status word of speed encoder in bit format:
Bit 00 - Encoder active 0 = No 1 = Yes
Bit 01 - Encoder fault 0 = No 1 = Yes
Bit 02 - Signal OK 0 = No 1 = Yes
Bit 03 - Encoder low speed loss 0 = No 1 = Yes
Bit 04 - Single edge measurement 0 = No 1 = Yes

Caution
When commissioning the closed-loop Vector control with sensor (VC) the frequency inverter
should first be operated with V/f control (p1300 = 0). When the motor is spinning and the
speed encoder connected (activated using p0400), parameters r0061 and r0021 must match
one another as far as the following quantities are concerned:
• Sign
• Absolute value (a deviation of a few percent is permitted)
The closed-loop Vector control with sensor (encoder) (p1300 = 21 or 23) may only be
activated if both conditions are fulfilled.
Ramp times (P1120 and 1121 can cause F90, encoder feedback loss).

Note
If the encoder is incorrectly connected, incorrect values will be displayed in r0061, r0063,
r0021 and r0022

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Operating Instructions, 11/2006, A5E00766042B AA 5-113
Commissioning (software)
5.10 Encoder Commissioning

5.10.2 Encoder fault codes

Description
The Encoder Interface has only one fault code, – F0090. This condition occurs when the
allowed frequency rate of change, set in P0492[3] is exceeded or when low speed encoder
loss is detected.

Note
The reason for the encoder loss will be given in the level 3 parameter P0949:
P0949 = 1 means encoder loss of channel A or channel B or channel A and channel B at
high speed (shaft speed > P0492)
P0949 = 2 means encoder loss of channel A or channel A and channel B at low speed
(shaft < P0492)
P0949 = 7 means excessive flux variance which may cause motor instability - possible due
to encoder loss.

Remedial action on fault condition

Should the encoder give a fault message F0090 the following remedial action should be
performed:
1. Check that an encoder is fitted. If the encoder is not fitted, set P0400 = 0 and select
SLVC mode (P1300 = 20 or 22).
2. Check the connections between the encoder and the inverter.
3. Check the encoder is not faulty (select P1300 = 0 and run at a fixed speed then check the
encoder feedback signal using r0061). Check for correct magnitude and direction of
speed.
4. Increase the encoder loss threshold in P0492.
5. Increase encoder low speed loss detection delay in P0494.

Control Units CU240S

5-114 Operating Instructions, 11/2006, A5E00766042B AA
Operation 6
6.1 General operation behavior

Overview
The operation and start-up behavior depends on the settings during commissioning of the
inverter.
As specific operation features the "Normal start-up behavior" and "Swap behavior" as well as
"up and download of parameter sets" are described in this section.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 6-1
Operation
6.2 Upload and download of parameter sets

6.2 Upload and download of parameter sets

Upload of parameter sets

With an upload, a parameter set can be saved in one of the following devices:
● PC (via STARTER)
● MMC
● OP

Note
The file format for the MMC is FAT. Any other format, such as FAT32 or NTFS are not
compatible with uploading and downloading parameter sets from the inverter.
Formatting can be accomplished using the DOS command line as follows:
C:\>format volume /FS:FAT - where volume has to be replaced by the name of the MMC
drive, for example A.
Please keep in mind that formatting will delete all the contents of the MMC.

An upload can be triggered via

● PROFIBUS
● OP
● STARTER
A detailed description is given in "Series Commissioning" in the commissioning section.

Download of parameter sets

In the case of a parameter download it is important to distinguish between the following
possibilities:
● Manual download
● Automatic download.

Control Units CU240S

6-2 Operating Instructions, 11/2006, A5E00766042B AA
 Operation
6.2 Upload and download of parameter sets

Caution
Parameter download between different types of control units and of different firmware
versions is not recommended.
Basically, it is possible to download parameter sets off different CU types, however, as
the parameter sets might differ, the user is fully responsible for the consistency of the
downloaded parameter set.
Therefore, the user has to take the responsibility in case of an automatic download by
acknowledging F0395.
During download of a parameter set from a MMC to the EEPROM of the Control Unit
CU240S (e.g. during serial commissioning) you have to note that the LEDs are flashing
correctly. If the Control Unit CU240S is in a fault state, the LEDs indicate this fault state
with higher priority than the download. It is not sure that the parameter set is downloaded
correctly.

Manual download
A manual download can be performed similar to an upload via
● PC (STARTER)
● MMC
● OP
It can be triggered like upload via
● PROFIBUS
● OP
● STARTER
With a manual download a parameter set without the fail-safe parameters is downloaded
from one of the above mentioned devices into the inverter.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 6-3
Operation
6.2 Upload and download of parameter sets

The manual download depends as follows on the settings of P8458.

Table 6-1 P8458 settings after a manual parameter download

P8458 setting in CU P8458 setting on P8458 setting after Remark

EEPROM download device download
0 0 0 ---
0 1 1 ---
0 2 2 ---
1 0 0 ---
1 1 1 ---
1 2 2 ---
2 0 0 ---
2 1 1 ---
2 2 2 ---

A detailed description is given in "Series Commissioning" in the commissioning section.

Automatic download
An automatic download needs a MMC to be performed. It is not possible to perform an
automatic download from a PC or from the OP.
The automatic download runs as follows according to the settings in P8458 after power cycle
or a after a swap (see "Start-up behavior" in this section).

Table 6-2 P8458 settings after an automatic parameter download from MMC

P8458 setting in CU P8458 setting on MMC P8458 setting after Remark

EEPROM start-up
0 0 0 Only possible in case of
0 1 0 swap

0 2 2
1 0 0 ---
1 1 0 ---
1 2 2 ---
2 0 0 ---
2 1 0 ---
2 2 2 ---

Contrary to a manual download even the fail-safe parameters are downloaded with an
automatic download.

Control Units CU240S

6-4 Operating Instructions, 11/2006, A5E00766042B AA
 Operation
6.2 Upload and download of parameter sets

Note
Manual and automatic download
With a manual download all necessary parameters excluding the fail-safe parameters (only
with Cus with fail-safe functions) are downloaded into the inverter. A detailed description is
given in "Series Commissioning" in the commissioning section.
With an automatic download even the fail-safe parameters are downloaded into the inverter.
An automatic download can only be performed with an MMC at Start-up or by swapping an
inverter component (CU or PM). A detailed description is given in "Start-up behavior" of this
section.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 6-5
Operation
6.3 Start-up Behavior

6.3 Start-up Behavior

Overview
When starting-up the inverter checks, whether an MMC is plugged in or not.
If it is plugged and no swap has been taken place the start-up runs according the "Normal
start-up behavior". If a component (CU or PM) has been replaced, this is called a swap and
the start-up will be performed according the "Swap behavior" of the inverter.

6.3.1 Normal Start-up behavior of the Inverter

Description
A normal start-up is a start-up after a power-cycle or a black-out. It can be performed with or
without MMC.

Normal start-up behavior without MMC

After a power-cycle or a black-out the inverter reads the parameters from EEPROM to RAM.

Normal start-up behavior with MMC

The CUs have been designed to detect automatically whether an MMC is present in the CU.
The interaction between the CU and the MMC is controlled using parameter P8458.
The possible settings for P8458 and their functions are given below.

P8458 = 0: No automatic parameter download from the MMC.

P8458 = 1: Automatic parameter download from the MMC only once (at the next start-up
of the CU (default setting)). After the download P8458 is set to 0.
P8458 = 2: Automatic parameter download from the MMC (if present) after each start-up
of the control unit.
On completion of the automatic download parameter P8458 will be set to 0 - if it was 1
before download - to prohibit any further automatic download of parameters. In this case the
MMC can be withdrawn after an automatic parameter download. For details to P8458
settings refer to "Upload and download of parameter sets" in this section.
If parameter P8458 is set to 1 or 2 and no MMC is present the inverter starts with the
parameters of the EEPROM without alarm or fault message.

Control Units CU240S

6-6 Operating Instructions, 11/2006, A5E00766042B AA
 Operation
6.3 Start-up Behavior

Note
MMC for "automatic download"
For an automatic download always the file clone00.bin will be used.
The user has to take care, that clone00.bin (saved as "clone00.bin" with STARTER via PC or
via setting P0804 = 00 with the OP) is available on the MMC, used for an automatic
parameter download at start-up. If clone00.bin does not exist drive will fail with F0061

Successful automatic download

After a successful automatic download, F0395 will be displayed.
● In case of a standard CU a confirmation is necessary.
● In the case of CUs with fail-safe functions, an acceptance test must be performed.
Confirmation
On standard CUs the current parameter set needs to be checked and confirmed by clearing
F0395. It can be cleared via:
● Digital input or PLC signal (depends on the settings of P0700)
● setting P7844 = 0.
● Via the button on the OP

Warning
The user is responsible for ensuring that the parameters held in the CU are the correct
parameters for their application.

Acceptance test
On CUs with fail-safe functions it is necessary to do an acceptance test (refer to the "Fail-
safe functions" section in this manual). To clear F0395 on CUs with fail-safe functions the
following procedure has to be followed:
● P0010 = 30
● P9761 = safety password
● P7844 = 0
● Carry out acceptance test

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 6-7
Operation
6.3 Start-up Behavior

Automatic download fault

If the automatic download process fails, the CU will return to the parameter set previously
held in the EEPROM and the following fault codes are generated:

Table 6-3 Automatic download fault codes

Fault code Description

F0061 Automatic download of parameters was not successful.
F0063 Automatic download of parameters was not successful (e.g. wrong CU).
In this case check, whether the MMC is defective, a parameter set clone00.bin is available,
or the parameter set is valid.

Notice
After upload and download of parameters between differing Control Units, the parameter
settings must be checked.
Parameter download from a different CU might fail with F0063 if parameters cannot be
downloaded (Check P949 for the (first) parameter number which cannot be downloaded).
If F0061 or F0063 occurs during startup it cannot be cleard except via a power cycle.

6.3.2 Swap Behavior of the Inverter

Overview
This section describes the possibilities to exchange inverter comonents, power modules or
control units, and the necesarry actions, depending on the swap type.
The following swaps are allowed:
● CU swap (neither PM nor CU powered)
● PM swap (neither PM nor CU powered)
● PM swap (CU externally powered)

Note
A swap is indicated by a F395. A downlaod fault during swap will be indicated by F0061
or F0063.
If F0061 or F0063 occurs during startup it cannot be cleard except via a power cycle.

Control Units CU240S

6-8 Operating Instructions, 11/2006, A5E00766042B AA
 Operation
6.3 Start-up Behavior

CU swap, PM swap (whether PM nor CU powered)

Constraints: MMC with valid Parameter set plugged
● Swap after power on detected, Parameter MMC -> RAM/EEPROM, inverter runs into
F0395
● Confirmation for standard CU or acceptance test in case of fail-safe CU required
constraints: no MMC
● Swap after power on detected, Parameter EEPROM -> RAM, inverter runs into F0395
● Commissioning recommended - otherwise inverter runs with parameter settings from
EEPROM
● Confirmation for standard CU or acceptance test in case of fail-safe CU required

PM swap (CU externally powered)

Constraints: MMC with valid Parameter set plugged
● Swap detected, Parameter MMC -> RAM/EEPROM, inverter runs into F0395
● Confirmation for standard CU or acceptance test in case of fail-safe CU required
Constraints: no MMC
● Swap detected, Parameter EEPROM -> RAM, inverter runs into F0395
● If the parameters, already held in the EEPROM are ok there is no commissioning
necesarry.
● Confirmation for standard CU or acceptance test in case of fail-safe CU required

Note
After a PM swap without MMC the parameter settings only stored in RAM will be lost

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 6-9
Operation
6.3 Start-up Behavior

Successful swap
After a successful swap, F0395 will be displayed.
● In case of a standard CU a confirmation is necessary.
● In the case of CUs with fail-safe functions, an acceptance test must be performed.
Confirmation
On standard CUs the current parameter set needs to be checked and confirmed by clearing
F0395. It can be cleared via:
● Digital input or PLC signal (depends on the settings of P0700)
● setting P7844 = 0.
● Via the button on the OP

Warning
The user is responsible for ensuring that the parameters held in the CU are the correct
parameters for their application.

Acceptance test
On CUs with fail-safe functions it is necessary to do an acceptance test (refer to the "Fail-
safe functions" section in this manual). To clear F0395 on CUs with fail-safe functions the
following procedure has to be followed:
● P0010 = 30
● P9761 = safety password
● P7844 = 0
● Carry out acceptance test

Swap fault
A swap fault is indicated if the automatic download fails. In this case, the CU will return to the
parameter set previously held in the EEPROM and F0395 as well as one of F0061, F0062
and F0063 will be generated.
First F0395 must be cleared via:
● Digital input or PLC signal (depends on the settings of P0700)
● setting P7844 = 0.
● Via the button on the OP
In the next step F0061 / F0062 or F0063 has to be cleared via power cycle.

Control Units CU240S

6-10 Operating Instructions, 11/2006, A5E00766042B AA
 Operation
6.3 Start-up Behavior

Note
F0395 cannot be cleared via power cycle. F0061, F0062 and F0063 can only be cleared via
power cycle.

In case of a swap fault check, whether the MMC is defective or a parameter set clone00.bin
is available or the parameter set is valid.
A valid parameter set means, it is not from a different type (eg. CU20S DP and CU240S or
failsafe and standard CUs)

Rules regarding swap and hot swap

There are a number of scenarios where a swap or hot swap can take place, each with their
own unique set of conditions that must be observed.

Danger
Do not attempt to hot swap a power module (PM)
Before attempting to swap a PM it must be fully powered-down. Any attempt to swap-out a
PM when power is still applied could result in death of personnel and severe damage to
property and equipment.

Warning
Swap restrictions
Before performing a swap take care of the following:
• It is the responsibility of the user to ensure that only CUs of the same type are swapped
• It is the responsibility of the user to ensure that the MMC contains the correct parameter
set
• It is the responsibility of the user to ensure that only PMs of the same type and power
rating are swapped.
• It is the responsibility of the user to ensure that the application is in a safe state before
any swap of equipment is performed.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 6-11
Operation
6.3 Start-up Behavior

Swapping a CU
The following procedure is given as a guide to perform a swap of a CU.

Caution
Data set compatibility
To ensure complete data set compatibility, it is recommended to perform an upload of the
parameter set from the CU to a new MMC prior to swapping the CU.

Before performing a CU swap take care of the following:

1. The PM is powered-down and disconnected.
2. Wait 5 minutes to allow the unit to discharge after switching off the line supply before
carrying out any installation work.
3. Remove the two-part terminals that are actually wired on the CU.
4. Remove the MMC.
5. Remove the CU from the PM.
Before switching on Power supply to the inverter take care of the following:
1. Fit the new CU to the PM.
2. Reconnect the two-part terminals to the CU.
3. Insert the MMC into the MMC-slot of the CU.

Swapping the PM

Caution
To ensure complete data set compatibility, make sure that all parameters are stored in the
EEPROM of the Control Unit (see P0014 or P0971) prior to swapping the PM).

Before performing a PM swap take care of the following:

1. The PM is powered-down and disconnected.
2. Wait 5 minutes to allow the unit to discharge after switching off the line supply before
carrying out any installation work.
Before switching on Power supply take care of the following:
1. The new PM is properly installed and connected.
2. The CU is fitted back on the PM.

Control Units CU240S

6-12 Operating Instructions, 11/2006, A5E00766042B AA
Service and maintenance 7
7.1 Service and support information

A&D Technical support

24-hour technical support is provided by four main centres worldwide.

A&D Global service and support

Europe/Africa (Erlangen)
Tel: +49 (180) 5050 222
Fax: +49 (180) 5050 223
Email: [email protected]

America (Johnson City)

Tel: +1 (423) 262 2552
Fax: +1 (423) 262 2589
Email: [email protected]

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 7-1
Service and maintenance
7.1 Service and support information

Asia/Pacific (Beijing)
Tel: +86 (1064) 757 575
Fax: +86 (1064) 747 474
Email: [email protected]

China (Beijing)
Tel: +86 (1064) 71 9990
Fax: +86 (1064) 71 9991
Email: [email protected]

Online Service and support

Comprehensive information and support tools are available from the Service and Support
internet site at:
http://support.automation.siemens.com

Contact address
Should any questions or problems arise while reading this manual, please contact Siemens
at the following address:
Siemens AG
Automation & Drives
A&D SD SPA PM4
Postfach 3269
D-91050 Erlangen
Germany
Email: [email protected]

Regional contacts
For questions regarding services, prices and conditions of technical support, please contact
your local Siemens partner.

Control Units CU240S

7-2 Operating Instructions, 11/2006, A5E00766042B AA
 Service and maintenance
7.2 Faults and Alarms

7.2 Faults and Alarms

Faults
In the event of a failure, the inverter switches off and the red LED "SF" will be on. The fault
code will be displayed via OP, STARTER or Communication interface (if fitted, resp.
connected).

Note
To reset the fault code, one of three methods listed below can be used:
1. Cycle the power to the inverter.
2. Press the Fn button on the OP
3. Use digital input 2 (default setting).
4. Set bit 7 in control word 1 (r0054)

Fault messages are stored in parameter r0947 under their code number (e.g. F0003 = 3).
The associated error value is found in parameter r0949. The value 0 is entered if a fault has
no error value. It is possible to read out the point in time that a fault occurred (r0948) and the
number of fault messages (P0952) stored in parameter r0947.
A detailed description of the fault messages is provided in the Parameter List.
The fault state indication by LEDs is shown in the following sections.

Alarm messages
The alarm code will be displayed via OP, STARTER or Communication interface (if fitted,
resp. connected). Alarm messages are stored in parameter r2110 under their code number
(e.g. A0503 = 503) and can be read out from there. A detailed description of the alarm
messages is provided in the Parameter List.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 7-3
Service and maintenance
7.3 LED Overview

7.3 LED Overview

Status display via LEDs

The SINAMICS G120 inverters provide multiple functions and operating states which are
indicated via LEDs.

6WDWXV/('RQ 6WDWXV/('RQ
&X6 &86'3)
&86'3

(QG 6DIH
5HDG\ 5HDG\ 6WDWH 6WRS

*HQHUDO %XV *HQHUDO %XV 6DIH 6DIHO\

)DXOW )DLOXUH )DXOW )DLOXUH 7RUTXH /LPLWHG
2II 6SHHG

Figure 7-1 State LEDs on the CU240S, CU240S DP, CU240S DP-F

Colours
The colours of the LEDs are self explanatory. The Status of the inverter is displayed by the
following different LED colours and states:

Meaning Color State

on off Temporary state
(flashing 0.5 Hz)
Fault indication LEDs Red
• SF
• BF
Ready LED Green
• RDY

Fail-safe LEDs Yellow

• ES
• STO, SS1, SLS
If for a certain state it is indifferent whether the LED is ON, OFF or flashing it is mentioned as
"not relevant".

Control Units CU240S

7-4 Operating Instructions, 11/2006, A5E00766042B AA
 Service and maintenance
7.3 LED Overview

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 operate by transmitting a
control-word.
This LED does not indicate whether the drive is running or not. For that purpose an OP
would be more convenient. The information of interest is the actual speed, which can be
displayed on an OP which can be easily plugged in and out at any time during operation.
● Bus-Failure LED (BF)
The Bus-failure LED indicates if any bus failure occurred. A bus failure can be
characterised as corrupted communication (e.g. a frame of the PROFIBUS) due to
signalling problems on the bus itself.
Note that faults according to the inner data structure of the transmitted communication
frames (e.g. CRC check of PROFIsafe telegram) are not denoted as bus failure. Thus,
such failures have to be indicated by the general fault LED.
The Bus-failure LED indicates the following states:
– Bus-failure LED off: no Bus failure
– Bus-failure LED on: no connection to the DP-Master (searching for baud rate)
– Bus-failure LED flashing 0.5 Hz: I/O device is not configured or is wrongly configured
(baud rate found, no data exchange).
● End-state LED (ES)
The end-state LED indicates if the end state of a triggered fail-safe function has been
reached
● Safe Torque Off LED (STO)
The safe torque off LED indicates the fail-safe function Safe Torque Off.
● Safe Stop 1 LED (SS1)
The safe stop 1 LED indicates the fail-safe function Safe Stop 1.
● Safely-Limited Speed LED (SLS)
The safely-limited speed LED indicates the fail-safe function Safely-Limited Speed.
For fail-safe functions please refer to section Function.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 7-5
Service and maintenance
7.4 Normal Status LEDs

7.4 Normal Status LEDs

Normal Status LEDs

Table 7-1 Status display

LED Description
SF RDY BF
red green red

not relevant Ready or running, conection to bus master ok

not relevant Ready or running, no connection to the bus master

not relevant Commissioning

not relevant General fault

not relevant not relevant Bus failure (search baud rate)

only valid for CU240S DP / CU240S DP-F

not relevant not relevant Bus failure (no data)

only valid for CU240S DP / CU240S DP-F

No supply available

Control Units CU240S

7-6 Operating Instructions, 11/2006, A5E00766042B AA
 Service and maintenance
7.5 Fail-Safe Function Status LEDs

7.5 Fail-Safe Function Status LEDs

STO Fail-safe function states via LED

LED Description
SF RDY BF ES STO SS1 SLS
red green red yellow
not relevant not relevant not relevant not relevant not relevant
STO parameterized

not relevant not relevant not relevant not relevant not relevant
STO reached

not relevant not relevant

LSTO triggered

SS1 Fail-safe function states via LED

LED Description
SF RDY BF ES STO SS1 SLS
red green red yellow
not relevant not relevant not relevant
SS1 parameterized

not relevant not relevant not relevant not relevant not relevant
SS1 triggered

not relevant not relevant not relevant not relevant not relevant SS1 reached,
STO reached,
end state for SS1

SLS Fail-safe function states via LED

LED Description
SF RDY BF ES STO SS1 SLS
red green red yellow
not relevant not relevant not relevant
SLS parameterized

not relevant not relevant not relevant not relevant not relevant
SLS triggered

not relevant not relevant not relevant not relevant not relevant
SLS reached

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 7-7
Service and maintenance
7.6 Further indication for LEDs

7.6 Further indication for LEDs

Further states, displayes via LED

LED Description
SF RDY BF ES STO SS1 SLS
red green red yellow
not relevant
Safety commissioning

not relevant Parameter download

from MMC

Control Units CU240S

7-8 Operating Instructions, 11/2006, A5E00766042B AA
 Service and maintenance
7.7 Troubleshooting with the PROFIBUS DP

7.7 Troubleshooting with the PROFIBUS DP

Overview
There are three types of diagnostic display:
● LEDs
● Alarm Numbers
● Diagnostic parameters.

Diagnostics using alarm numbers

If a Operator Panel (OP) is fitted to the Control Unit and a alarm or fault condition occurs, the
OP will display the appropriate alarm or fault number.
If an alarm occurs, the alarm number will be displayed and the inverter will continue to run,
although it is possible that it may run in an unexpected manner depending upon the alarm
condition.
If a fault occurs, the fault number will be displayed and normally the inverter will be stopped.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 7-9
Service and maintenance
7.7 Troubleshooting with the PROFIBUS DP

Table 7-2 Alarm numbers, cause and remedy

Alarm Meaning
Number
A0700 Cause The parameter or configuring settings by the PROFIBUS master are
invalid.
Remedy Correct the PROFIBUS configuration
A0702 Cause The link to the PROFIBUS is interrupted.
Remedy Check connector, cable and PROFIBUS master.
A0703 Cause No setpoints or invalid setpoints (control word = 0) are being received
from the PROFIBUS master.
Remedy Check setpoints from the PROFIBUS master. Switch SIMATIC CPU to
"RUN".
A0704 Cause At least one configured internode transmitter is not yet active, or has
failed.
Remedy Activate internode transmitter.
A0705 Cause No actual values received from inverter.
Remedy None (fault is with the inverter).
A0706 Cause PROFIBUS DP software error.
Remedy None diagnostic parameter r2041.
A0710 Cause Inverter has detected failure of PROFIBUS communications link.
Remedy Communication interface on Control Unit may be broken.
A0711 Cause Invalid value of PROFIBUS parameter.
Remedy Check P0918 address and P2041.
F0070 Cause No communication via PROFIBUS. Triggered by A0702, A0703 and
A0704. The telegram failure time set in P2040 has run out. Details see
section "Faults and Alarns" in the Parameter List.
Remedy Check connection of the communication devices and ensure that a
valid control word is being used.

Identification of the communications components

The read-only parameter r2053 shows the information by which the various firmware
components of the PROFIBUS DP interface can be identified.

Table 7-3 Identification of communications firmware

Parameter Meaning
r2053.00 0: Inverter cannot identify the communications interface
1: PROFIBUS DP detected
2: Not assigned
56: Undefined communications error
r2053.01 Firmware version
r2053.02 Constant "0"
r2053.03 Firmware date (year)
r2053.04 Firmware date (day and month)

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 Service and maintenance
7.7 Troubleshooting with the PROFIBUS DP

Standard diagnostics
When the parameter P2041.03 = 0, then by using the read-only parameter r2054 and it’s
indices, it is possible to obtain detailed diagnostic information regarding the PROFIBUS DP
interface. This information is listed in table below.

Table 7-4 Standard diagnostics

Parameter Meaning
r2054.00 PROFIBUS DP status:
0: Off
1: Baud rate search
2: Baud rate found
3: Cyclical data exchange
(> 100: other diagnostic screen active)
r2054.02 Number of acyclical links with class 2 master (PC, OP): 0 … 2
r2054.03 Error number of last unsuccessful parameter access operation through an acyclical
link.
r2054.04 Parameter number of last unsuccessful parameter access operation
r2054.05 Sub-index of last unsuccessful parameter access operation
When parameter accessing errors occur, r2054.03 display the appropriate error number,
these are listed in table below.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 7-11
Service and maintenance
7.7 Troubleshooting with the PROFIBUS DP

Table 7-5 Parameter accessing error numbers

Number Cause Remedy

0 … 199: Parameter access has been converted to a PKW request. Error detected in the
inverter. Additional information is in r2054.05 and r2054.06: Parameter number,
index word
0 Parameter number does not exist Check data block number
1 Parameter number cannot be modified --
2 Minimum/maximum not reached or exceeded --
3 Sub-index does not exist Check data block offset
4 Access of single value with array identifier Set data block offset = 0
5 Access to word with double word request or vice Use correct data type
versa (e.g. INT for word, DINT for
double word)
6 Setting not allowed (resetting only) --
7 Descriptive element cannot be modified --
11 No status as master control --
12 Key word missing --
17 Request cannot be processed due to operating --
state
101 Parameter number currently deactivated --
102 Channel not wide enough --
104 Illegal parameter value --
106 Request not implemented --
200/201 Modified minimum or maximum not reached or Minimum or maximum can be
exceeded. further limited in operation
240 … 249: Parameter access is incorrectly formatted. Error detected on the PROFIBUS DP.
Additional information in r2054.05 and r2054.06: Parameter number or S7 data block
number, sub-index or S7 data block offset.
240 Error in variable address (no additional Legal: "Data block" area
information)
241 Data block number illegally formatted Legal: 1 … 31999
242 Data block offset illegally formatted Legal: 0 … 116
243 Illegal "type" Legal: CHAR, BITE, INT,
WORD, INT, DWORD, REAL
244 Illegal "Number of elements" on accessing Legal: Effectively 2 or 4 bytes
parameter value
248 Illegal text/description modification --
249 Inconsistency in write request: "Type" and Error in communication device
"Number of elements" does not match "Data type"
and "Data length"
250: Parameter access has been converted to a PKW request. Response from inverter is
seen as incorrect. Error detected on the PROFIBUS DP. Additional information can
be seen in r2054.05 and r2054.06.
250 PKW response does not match request Error in the inverter
251: Error detected on the PROFIBUS DP; no additional information
251 Response too long for response telegram Error in communication device

Control Units CU240S

7-12 Operating Instructions, 11/2006, A5E00766042B AA
 Service and maintenance
7.8 Troubleshooting with the OP

7.8 Troubleshooting with the OP

Description
If the motor fails to start when the ON command has been given:
● Check that P0010 = 0.
● Check the inverter state via r0052
● Check command and setpoint source (P0700 and P1000)
Warnings and faults are displayed on the OP with Axxx and Fxxx respectively. The individual
messages are shown in the Parameter List.

Note
Motor data must relate to the inverter data power range and voltage.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 7-13
Functions 8
8.1 BICO Technology

Interconnecting signals (BICO)

A state-of-the-art inverter must be able to interconnect internal and external signals (setpoint
or actual values and control or status signal). This interconnection functionality must have a
high degree of flexibility in order to be able to adapt the inverter to new applications. Further,
a high degree of usability is required, which also fulfills standard applications. To fulfill these
requirements BICO technology and fast parameterization using parameters P0700/P1000
are used.

8.1.1 Selection of command/setpoint source P0700 and P1000

Description
The following parameters can be used to quickly interconnect setpoints and control signals:
● P0700 Selection of command source
● P1000 Selection of setpoint source
These parameters are used to define through which interface the inverter receives the
setpoint or the power-on/power-off command. The interfaces, shown in the table below can
be selected for the command source P0700.

Table 8-1 Parameter P0700

Parameter Values Significance/command source

0 Factory default
1 Operator Panel (OP)
2 Terminal
4 USS on RS232
5 USS on RS485
6 Fieldbus

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-1
Functions
8.1 BICO Technology

The following internal or external sources or interfaces can be selected for the frequency
setpoint source P1000. In addition to the main setpoint (second position), a supplementary
setpoint (first position) can be selected. This is shown in the table below.

Table 8-2 Parameter P1000

Parameter Values Significance

Main setpoint source Supplementary setpoint source
0 No main setpoint --
1 MOP setpoint (motorized potentiometer) --
2 Analog setpoint --
3 Fixed frequency --
4 USS on RS232 --
5 USS on RS485 --
6 Fieldbus --
7 Analog setpoint 2 --
10 No main setpoint MOP setpoint
11 MOP setpoint MOP setpoint
12 Analog setpoint MOP setpoint
… … …
77 Analog setpoint 2 Analog setpoint 2

Note
The complete list of all the possible settings is contained within Parameter Manual (see
P1000).

The selection of the command source is made independently of the selection of the
frequency setpoint source. This means that the source to enter the setpoint does not have to
match the source to enter the power-on/power-off command (command source). This
means, for example, that the frequency setpoint P1000 = 6 can be connected using an
external device and ON/OFF is entered using digital inputs DI (terminals, P0700 = 2).

Caution
When P0700 or P1000 are modified, then the frequency inverter also changes the
subordinate BICO parameters (refer to the Parameter Manual for P0700 or P1000 in the
appropriate tables).
There is no prioritization (priority assignment) between direct BICO parameterization and
P0700/P1000. The last modification is valid.

Control Units CU240S

8-2 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.1 BICO Technology

8.1.2 Using BICO technology

Description
Using BICO technology (Binector Connector Technology), process data can be freely
interconnected using the "standard" inverter parameterization. For this all values which can
be freely interconnected (for example, frequency setpoint, frequency actual value, current
actual value, etc.) are defined as "Connectors" and all digital signals which can be freely
interconnected (for example, status of a digital input, ON/OFF, message function when a
limit is violated etc.) are defined as "Binectors".
There are many input and output quantities as well as quantities within the closed-loop
control which can be interconnected in a inverter. It is possible to adapt the inverter to the
various requirements using BICO technology.
A binector is a digital (binary) signal without any units and which can either have the value of
0 or 1. Binectors always refer to functions and are sub-divided into binector inputs and
binector outputs (see the table below). In this case, the binector input is always designated
using a "P" parameter (e.g. P0840 BI: ON/OFF1), while the binector output is always
represented using an "r" parameter (e.g. r1025 BO: FF status).
As can be seen from the examples above, the binector parameters have the following
abbreviations in front of the parameter names:

BI: Binector Input, signal sink ("P" parameters)

The BI parameter can be interconnected with a binector output as a source, by entering the
parameter number of the binector output (BO parameter) as a value in the BI parameter.

BO: Binector Output, signal source ("r" parameters)

The BO parameter can be used as a source for BI parameters. For a particular
interconnection the BO parameter number must be entered into the BI parameter.

Example
Interconnecting the BO parameter r1025 with BI parameter P0840: → P0840 = 1025

Table 8-3 Binectors

Abbreviation and symbol Name Function

BI Binector input 'DWDIORZ
(signal sink) 3[[[[
)XQFWLRQ
%,
'DWDIORZ
BO Binector output
(signal source) U[[[[
)XQFWLRQ
%2

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-3
Functions
8.1 BICO Technology

A connector has a value (16 or 32 bit), which can include a normalized quantity (without
dimension) as well as a quantity with associated units. Connectors always refer to functions
and are sub-divided into connector inputs and connector outputs. Essentially it is the same
as for the binectors, the connector inputs are characterized by a "P" parameter (e.g. P0771
CI: AO (analog output)); while the connector outputs are always represented using an "r"
parameter (e.g. r0021 CO: Act. frequency).
As can be seen from the examples above, connector parameters have the following
abbreviations in front of the parameter names:

CI: Connector Input, signal sink ("P" parameters)

The CI parameter can be interconnected with a connector output as a source, by entering
the parameter number of the connector output (CO parameter) as a value in the CI
parameter.

CO: Connector Output, signal source

The CO parameter can be used as source for CI parameters. For a particular
interconnection, the CO parameter number must be entered in the CI parameter.
Example: Interconnecting the CO parameter r0021 with CI parameter P0771: → P0771 = 21

Further, there are "r" parameters where several binector outputs are combined in a word
(e.g. r0052 CO/BO: Status word 1). This feature reduces, on one hand, the number of
parameters and simplifies parameterization using the serial interface (data transfer). These
parameters are further characterized by the fact that they do not have any units and each bit
represents a digital (binary) signal.
As can be seen from the examples of parameters, these combined parameters have the
following abbreviation in front of the parameter names:

CO/BO: Connector Output/Binector Output, signal source ("r")

CO/BO parameters can be used as a source for CI parameters and BI parameters:
● In order to interconnect all of the CO/BO parameters, the parameter number must be
entered into the appropriate CI parameter (e.g. P2016[0] = 52).
● When interconnecting a single digital signal, in addition to the CO/BO parameter number,
the bit number must also be entered into the CI parameter (e.g. P0731 = 52.3)

Control Units CU240S

8-4 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.1 BICO Technology

Table 8-4 Connectors

Abbreviation and symbol Name Function

CI Connector input 'DWDIORZ
(signal sink) 3[[[[
)XQFWLRQ
&,
CO Connector output 'DWDIORZ
(signal source) U[[[[
)XQFWLRQ
&2
'DWDIORZ
CO Binector/connector output
BO (signal source) U[[[[
)XQFWLRQ

&2%2

In order to interconnect two signals, a BICO setting parameter (signal sink) must be
assigned the required BICO monitoring parameter (signal source). A typical BICO
interconnection is shown using the following examples (see figure below):

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Figure 8-1 BICO connections

Note
BICO parameters with the CO, BO or CO/BO attributes can be used a number of times.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-5
Functions
8.2 Data Sets

8.2 Data Sets

Description
For many applications it is advantageous if several parameters can be simultaneously
changed, during operation or in the ready state, using an external signal.
This functionality can be elegantly implemented using indexed parameters. In this case, as
far as the functionality is concerned, the parameters are combined to form groups/data sets
and are indexed. By using indexing, several different settings can be saved for each
parameter which can be activated by changing-over the data set (i.e. toggling between
indexes).
The following data sets apply:
● Command Data Set CDS
● Drive Data Set DDS
Three independent settings are possible for each data set. These settings can be made
using the index of the particular parameter:
● CDS0 … CDS2
● DDS0 … DDS2

Command Data Set

Those parameters (connector and binector inputs) which are used to control the inverter and
enter a setpoint, are assigned to the command data set (CDS). The signal sources for the
control commands and setpoints are interconnected using BICO technology. For that the
connector and binector inputs are assigned corresponding to the connector and binector
outputs as signal sources. A command data set includes:

Command sources and binector inputs for control commands (digital signals) e.g.
Selects the command source P0700
ON/OFF1 P0840
OFF2 P0844
JOG Enable P1057
Enable JOG right P1055
Enable JOG left P1056

Setpoint sources and connector inputs for setpoints (analog signals) e.g.
Selection of frequency setpoint P1000
Selection of main setpoint P1070
Selection of additional setpoint P1075

Control Units CU240S

8-6 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.2 Data Sets

The parameters, combined in a command data set, are designated with [x] in the parameter
list in the index field.

Index
Pxxxx[0] Command data set 0 (CDS0)
Pxxxx[1] Command data set 1 (CDS1)
Pxxxx[2] Command data set 2 (CDS2)

Note
A complete list of all of the CDS parameters is contained in the Parameter Manual.

It is possible to parameterize up to three command data sets. This makes it easier to toggle
between various pre-configured signal sources by selecting the appropriate command data
set. A frequent application involves, for example, the ability to toggle between automatic and
manual operation.

Note
The parameters will be altered during data set switchover in the state "Ready" and "Run".
The following parameters will not be changed in the state "run:
P0700, P0701, P0702, P0703, P0704, P0705, P0706, P0707, P0708, P0709, P0712, P0713,
P0719, P0800, P0801, P0840, P0842, P0844, P0845, P0848, P0849, P0852, P1000, P1020,
P1021, P1022, P1023, P1035, P1036, P1055, P1056, P1070, P1071, P1075, P1076, P1110,
P1113, P1124, P1140, P1141, P1142, P1330, P1500, P1501, P1503, P1511, P1522, P1523,
P2103, P2104, P2106, P2220, P2221, P2222, P2223, P2235, P2236.

SINAMICS G120 has an integrated copy function which is used to transfer command data
sets.
This can be used to copy CDS parameters corresponding to the particular application.
P0809 is used to control the copy operation as follows:

Copy operation controlled with P0809

P0809[0] Number of the command data set which is to be
copied (source)
P0809[1] Number of the command data set into which data
is to be copied (target)
P0809[2] Copying is started, if P0809[2] = 1
Copying has been completed, if P0809[2] = 0

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-7
Functions
8.2 Data Sets

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3
3
3
3
3
   
   
   
3
3
3
&'6 &'6 &'6

Figure 8-2 Copying from a CDS

The command data sets are changed-over using the BICO parameters P0810 and P0811,
whereby the active command data set is displayed in parameter r0050 (see figure below).
Changeover is possible both in the "Ready" as well as in the "Run" states.

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Figure 8-3 Changing-over a CDS

The currently active command data set (CDS) is displayed using parameter r0050:

selected active
CDS CDS
r0055 r0054 r0050
Bit15 Bit15
CDS0 0 0 0
CDS1 0 1 1
CDS2 1 0 2
CDS2 1 1 2

Figure 8-4 Active command data set (CDS)

Example
The command source (e.g. terminals → OP) or setpoint (frequency) source (e.g. AI → MOP)
should be changed-over using a terminal signal (e.g. DI3) as a function of an external event

Control Units CU240S

8-8 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.2 Data Sets

(e.g. the higher-level control unit fails). A typical example in this case is a mixer, which may
come to an uncontrolled stop when the control fails.

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6HWSRLQWIUHTXHQF\VRXUFH $,!023
P0810 = 722.3
DI3
P0700[0] = 2 0
Terminals Sequence control
P0700[1] = 1 1
OP

P1000[0] = 2 0
AI Setpoint Motor
channel control
P1000[1] = 1 1
MOP

Figure 8-5 Changing-over between the control and setpoint source

CDS0: Command source via terminals and setpoint source via analog input (AI)
CDS1: Command source via OP and setpoint source via MOP
CDS changeover is realized using digital input 3 (DI3)
Commissioningsteps:
1. Carry-out commissioning for CDS0 (P0700[0] = 2 and P1000[0] = 2)
2. Connect P0810 (P0811 if required) to the CDS changeover source
(P0704[0] = 99, P0810 = 722.3)
3. Copy from CDS0 to CDS1 (P0809[0] = 0, P0809[1] = 1, P0809[2] = 1)
4. Adapt CDS1 parameters (P0700[1] = 1 and P1000[1] = 1)

Drive data set

The drive data set (DDS) contains various setting parameters which are of significance for
the open-loop and closed-loop control of a motor:

Drive and encoder data, e.g.

Select motor type P0300
Rated motor voltage P0304
Main inductance P0360
Select encoder type P0400

Various closed-loop control parameters, e.g.

Fixed frequency 1 P1001
Min. frequency P1080
Ramp-up time P1120
Control mode P1300

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-9
Functions
8.2 Data Sets

The parameters, combined in a drive data set, are designated with an [x] in the parameter
list in the index field:

Index
Pxxxx[0] Drive data set 0 (DDS0)
Pxxxx[1] Drive data set 1 (DDS1)
Pxxxx[2] Drive data set 2 (DDS2)

Note
A complete list of all of the DDS parameters is contained in the Parameter Manual.

It is possible to parameterize several drive data sets. This makes it easier to toggle between
various inverter configurations (control mode, control data, motors) by selecting the
appropriate drive data set (see figure below).

Note
The parameters will be altered during data set switchover in the state "Ready" and "Run".
The following parameters will not be changed in the state "run": P0300, P0304, P0305,
P0307, P0308, P0309, P0310, P0311, P0314, P0320, P0335, P0340, P0400, P0405, P0408,
P0410, P0491, P0492, P0500, P1082, P1240, P1256, P1300, P1320, P1322, P1324, P1820,
P2000, P2001, P2002, P2003, P2004, P2181.

Just like the command data sets, it is possible to copy drive data sets within the SINAMICS
G120. P0819 is used to control the copy operation as follows:

Copy operation controlled with P0819

P0819[0] Number of the drive data set which is to be
copied (source)
P0819[1] Number of the drive data set into which data is to
be copied (target)
P0819[2] Copying is started, if P0819[2] = 1
Copying has been completed, if P0819[2] = 0

Control Units CU240S

8-10 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.2 Data Sets

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Figure 8-6 Copying from a DDS

Drive data sets are changed-over using the BICO parameter P0820 and P0821 whereby the
active drive data set is displayed in parameter r0051 (see figure below). Drive data sets can
only be changed-over in the "Ready" state and this takes approximately 50 ms.

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Figure 8-7 Changing-over a DDS

The currently active drive data set (DDS) is displayed using parameter r0051[1]:

selected active
DDS DDS
r0055 r0055 r0051 [0] r0051 [1]
Bit05 Bit04
DDS0 0 0 0 0
DDS1 0 1 1 1
DDS2 1 0 2 2
DDS2 1 1 2 2

Figure 8-8 Active drive data set (DDS)

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-11
Functions
8.2 Data Sets

Example
The inverter should be switched-over from motor 1 to motor 2.

0 0RWRU

.
*

0 0RWRU
.

Figure 8-9 Changeover from motor 1 to motor 2

Commissioning steps with 2 motors (motor 1, motor 2):

1. Carry-out commissioning at DDS0 with motor 1; adapt the remaining DDS0 parameters.
2. Connect P0820 (P0821 if required) to the DDS changeover source
(e.g. via DI4: P0705[0] = 99, P0820 = 722.4).
3. Changeover to DDS1 (check using r0051).
4. Carry-out commissioning at DDS1 with motor 2; adapt the remaining DDS1 parameters.

Control Units CU240S

8-12 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.3 Digital inputs (DI)

8.3 Digital inputs (DI)

Data

Quantity: 6 … 9 + 2 (depends on CU variant)

Parameter range: P0701 … P0712, P0713
r0720 … P0724
Function chart number: FP2000, FP2200
Features:
• cycle time: 2 ms
• switch-on threshold: 9.6 V
• switch-out threshold: 8.6 V
• electrical features: electrically isolated, short-circuit proof

Description
External control signals are required for an inverter to be able to operate autonomously.
These signals can be entered using a serial interface as well as using digital inputs (see
figure below). The SINAMICS G120 has depending on CU variant up to 9 digital inputs which
can be expanded by using the 2 analog inputs. The digital inputs can be freely programmed
to create a function. Regarding the programming, it is possible to directly assign the function
using parameters P0701 … P0713 or to freely program the function using BICO technology.

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Figure 8-10 Digital inputs

The number of available digital inputs is displayed in parameter r0720. The logical states of
the digital inputs can be de-bounced using P0724 and read-out using parameter r0722
(BICO monitoring parameter). Further, this parameter is used for BICO parameterization of
the digital inputs (refer to BICO parameterization in the following section).

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-13
Functions
8.3 Digital inputs (DI)

Digital inputs and analog inputs used as digital inputs

Following digital inputs are available:

• CU240S and CU240S DP: DP P0701 … P0709,

P0712, P0713 analog inputs used as digital inputs
• CU240S DP-F: DP P0701 … P0706,
P0712, P0713 analog inputs used as digital inputs
Each digital input can be used as listed in the table below:

Table 8-5 Possible settings of the digital inputs and analog inputs used as digital inputs

Parameter Significance
Value
0 Digital input disabled
1 ON/OFF1
2 ON_REV/OFF1
3 OFF2 – coast to standstill
4 OFF3 – quick ramp-down
9 Fault acknowledge
10 JOG right
11 JOG left
12 Reverse
13 MOP up (increase frequency)
14 MOP down (decrease frequency)
15 Fixed frequency selector Bit 0
16 Fixed frequency selector Bit 1
17 Fixed frequency selector Bit 2
18 Fixed frequency selector Bit 3
25 Enable DC braking
27 Enable PID
29 External trip
33 Disable additional frequency setpoint
99 Enable BICO parameterization

Example
An ON/OFF1 command is to be accomplished using digital input DI0.
● P0700 = 2 Control enabled using the terminal strip (digital inputs)
● P0701 = 1 ON/OFF1 using digital input 0 (DI0).

Control Units CU240S

8-14 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.3 Digital inputs (DI)

Note
If an analog input has been configured as a digital input, then the following limit values
apply:
• Voltage > 4 V = logical 1
• Voltage < 1.6 V = logical 0

BICO parameterization
If the setting 99 (BICO) is entered into parameters P0701 … P07013, then the BICO wiring is
enabled for the appropriate digital input. The output parameter number of the function (the
parameter, included in the parameter text BO) should be entered into the command source
(the parameter which contains the code BI in the parameter text).

Example
A relay is to be controlled directly using DI0.
● P0700 = 2 Control enabled using digital inputs
● P0701 = 99 Enable BICO parameterization on DI0
● P0731[0] = 722.0 Relay 1 controlled directly.
This can be useful when the normal relay functions and digital inputs are not required so the
user can use them for their own purposes.

Note
Only experienced users should use the BICO parameterization and for applications where
the possibilities provided by P0701 … P07013 are no longer adequate.
If P0701 … P07013 are set to 99, then the command source can only be changed by the use
of P0700. For example, changing P0701 from 99 to 1 will not change the command source
or alter the existing BICO settings.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-15
Functions
8.4 Digital outputs (DO)

8.4 Digital outputs (DO)

Data

Quantity: 3
Parameter range: r0730 … P0748
Function chart number: FP2100
Features:
• cycle time: 10 ms

Description
Three output relays are provided which can be programmed to indicate a variety of states of
the inverter, such as faults, warnings, current limit conditions, etc.
Some of the more popular settings are pre-selected (see table below), but others can be
allocated using the BICO internal connection feature.

Relay:
max. opening/closing time: 5/10 ms
voltage/current 30 V DC/0.5 A maximum

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Figure 8-11 Digital outputs

The states, which are to be output, are defined using the "BI" parameters P0731 (digital
output 0), P0732 (digital output 1) and P0733 (digital output 2). For the definition, the "BO"
parameter number or "CO/BO" parameter number and the bit number of the particular state

Control Units CU240S

8-16 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.4 Digital outputs (DO)

should be entered into P0731 … P0733. Frequently used states including the parameter
number and bit are shown in the table below.

Table 8-6 Parameters P0731 to P0733 (frequently used functions/states)

Parameter value Significance

52.0 Drive ready
52.1 Drive ready to run
52.2 Drive running
52.3 Drive fault active
52.4 OFF2 active
52.5 OFF3 active
52.6 ON inhibit active
52.7 Drive warning active
52.8 Deviation, setpoint/actual value
52.9 PZD control
52.10 f_act >= P1082 (f_max)
52.11 Warning: Motor current limit
52.12 Brake active
52.13 Motor overload
52.14 Motor runs right
52.15 Inverter overload
53.0 DC brake active
53.1 f_act < P2167 (f_off)
53.2 f_act > P1080 (f_min)
53.3 Actual current r0027 ≥ P2170
53.6 f_act ≥ setpoint (f_set)

Note
On the OP the bit numbers are displayed in hex-format (0..9, A..F).
For complete list of all of the binary status parameters (refer to "CO/BO" parameters) in the
Parameter Manual.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-17
Functions
8.5 Analog inputs (A/D converter)

8.5 Analog inputs (A/D converter)

Data

Quantity: 2
Parameter range: P0750 … P0762
Function chart number: FP2200
Features:
• cycle time: 4 ms
• resolution: 10 bits
• accuracy: 1 % referred to 10 V / 20 mA
• electrical features: incorrect polarity protection, short-circuit
proof

Description
Analog setpoints, actual values and control signals are read-into the inverter using the
appropriate analog inputs and are converted into digital signals or values using the A/D
converter.
The setting as to whether the analog input is a voltage input (10 V) or a current input (20 mA)
must be selected using the general I/O DIP switch on the control unit as well as also using
parameter P0756 (for details refer to Chapter "Installing/Mounting" Section "Connecting the
Control Unit via terminals").

Note
The setting of P0756 (analog input type) must match that selection on the DIP switch on the
control unit.
The bipolar voltage input is only possible with analog input 0 (AI0).

Control Units CU240S

8-18 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.5 Analog inputs (A/D converter)

Depending on the AI type or source, the appropriate connection must be made. Using, as an
example, the internal 10 V voltage source, a connection is shown in the figure below.

./9 ./9

./9 ./9

./$, P$ ./$,

!N˖ $ $
./$, ./$,
' '

./$, ./$,
$ $
./$, ./$,
' '

Figure 8-12 Example of a connection for AI voltage and current input

The AI channel has several function units (filter, scaling, dead zone, see figure below).

3
3
3
3
U 3
',3VZLWFK 3 3 3
)XQFWLRQ
./
$, $, $ $, $, $,
VFDOLQJ GHDG]RQH U 3[[[[
./ W\SH ' W\SH
$,
U

 U
 U;

Figure 8-13 AI channel

Note
When the filter time constant P0753 (AI-PT1) is increased, this smooths the AI input signal
therefore reducing the ripple. When this function is used within a control loop, this smoothing
has a negative impact on the control behavior and immunity to noise (the dynamic
performance deteriorates).

Note
The analog inputs can be used as digital inputs. Setting P0712 and P0713 > 0 assign digital
input functions to the analog inputs.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-19
Functions
8.6 Analog outputs (D/A converter)

8.6 Analog outputs (D/A converter)

Data

Quantity: 2
Parameter range: r0770 … P0785
Function chart number: FP2300
Features:
• cycle time: 4 ms
• resolution: 12 bit
• accuracy: 1 % referred to 20 mA

Description
Two analog outputs are provided which can be programmed to indicate a variety of
variables. Some of the more popular settings are pre-selected (see table below), but others
(BICO outputs) can be allocated using the BICO internal connection feature.

Table 8-7 Pre-set analog outputs

Parameter Description
r0020 CO: Frequency setpoint before RFG
r0021 CO: Actual filtered frequency
r0024 CO: Actual filtered output frequency
r0025 CO: Actual filtered output voltage
r0026 CO: Actual filtered DC-link voltage
r0027 CO: Actual filtered output current
… …
r0052 CO/BO: Actual status word 1
r0053 CO/BO: Actual status word 2
r0054 CO/BO: Actual control word 1
… …
In order to adapt the signal, the D/A converter channel has several function units (filter,
scaling, dead zone) which can be used to modify the digital signal before conversion (see
figure below).

Control Units CU240S

8-20 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.6 Analog outputs (D/A converter)

3
3
3
3
U
3 3
3

P$
$2 $2 '
)XQFWLRQ U[[[[ 3 $2
VFDOLQJ GHDG]RQH
$ $2

1 U
0 U

Figure 8-14 D/A converter channel

Note
The analog output 0 (AO0) can be changed-over from current output (P0776 = 0) to voltage
output (P0776 = 1).
The analog output 1 (AO1) only provide current output (0 … 20 mA). The 0 … 10 V voltage
signal can be generated by connecting a 500 Ω resistor across the outputs. The voltage drop
across the resistor can be read using parameter r0774 if the parameter P0776 is changed-
over from current output (P0776 = 0) to voltage output (P0776 = 1). The D/A scaling
parameters P0778, P0780 and the D/A converter dead zone must still be entered in mA (0
… 20 mA).

With setting parameter P0775 = 1 it is possible to detect negative values on the input side of
the D/A converter channel. If enabled, this parameter will take the absolute value of the
value to be outputed (the AO-linear characteristic is mirrored on the y axis). If the value was
originally negative then the corresponding bit in r0785 is set.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-21
Functions
8.7 Communication via USS

8.7 Communication via USS

Data

Parameter range: P2010 … r2037

Warnings: –
Faults: F0071, F0072
Function chart number: FP2500, FP2510, FP2600, FP2610

Description
Using the Universal Serial Interface (USS) protocol, a user can establish a serial point-to-
point data link (RS232 interface) and a serial bus data link between a higher-level master
system and several slave systems (RS485 interface). Master systems can be e.g. PLCs (e.g.
SIMATIC S7-200) or PCs. The inverters are always the slaves on the bus system.
The USS protocol allows the user to implement both automation tasks with cyclical telegram
traffic (a fixed telegram length is necessary) as well as visualization tasks. In this case, the
protocol with variable telegram length is advantageous, as texts and parameter descriptions
can be transferred in one telegram without chopping up the information.
With the RS232 interface only direct connections (point-to-point) are possible with cable
lengths of 2 m … 5 m typically. This is typically used to commission a drive where the
commissioning software (e.g. STARTER) runs on a PC. For this configuration the optional
PC Connection Kit is available.
With the RS485 interface simple and cheap networks can be constructed. The topology must
be that of a line with the first and last devices of the line terminated with termination
resistors.

RS485 connector
6 3 8 5
620 Ω 120 Ω 620 Ω

Figure 8-15 Termination resistors

Control Units CU240S

8-22 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.7 Communication via USS

Short branches are possible to connect the devices. Up to 31 inverters can be integrated as
slaves into a network with a PLC as master.

* * *

56WHUPLQDWRU
&8 &8 &8
56WHUPLQDWRU

0DVWHU

  56      
56
6FUHHQLQJ 6FUHHQLQJ 6FUHHQLQJ 56

Figure 8-16 USS network

Cable Lengths and number of devices

Table 8-8 Max. number of devices and max. cable length

Baudrate in bit/s Max Number of Devices Max Cable Length

9600 32 1200 m
19200 32 1200 m
38400 32 1200 m
57600 32 1200 m
187500 30 1000 m

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-23
Functions
8.7 Communication via USS

8.7.1 Structure of a USS telegram

Description
The following figure shows the structure of a typical USS telegram. It consists of a start
delay, 4 framing bytes (STX, LGE, ADR and BCC) and the n user data.

STX LGE ADR 1. 2. ::: n. BCC

6WDUW'HOD\ n user data

Figure 8-17 Structure of USS telegram

A typical frame consists of:

STX 1 Byte
LGE 1 Byte
ADR 1 Byte
BCC 1 Byte
PKW 8 Bytes (4 Words: PKE + IND + PWE1 + PWE2)
PZD 4 Bytes (2 Words: PZD1 + PZD2)
Sum : 16 Bytes

Start Delay
The length of the start delay is at least the time of two characters and depends on the
baudrate.

Table 8-9 Length of start delay

Baudrate in bit/s Transfer time per character (= 11 bit) Transfer time per bit Min. Start Delay
9600 1.146 ms 104.170 µs > 2.291 ms
19200 0.573 ms 52.084 µs > 1.146 ms
38400 0.286 ms 26.042 µs > 0.573 ms
57600 0.191 ms 17.361 µs > 0.382 ms
187500 0.059 ms 5.340 µs > 0.117 ms
Note: The time between characters must be smaller than the start delay.

STX
The STX field is a single byte ASCII STX character (0x02) used to indicate the start of a
message.

Control Units CU240S

8-24 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.7 Communication via USS

LGE
The LGE is a single byte field indicating the number of bytes, which follow this in the
message. According to the USS specification, the telegram length is variable, and the length
must be specified in the 2nd telegram byte (i.e. LGE). Depending on the configuration, fixed
telegram lengths can be defined (see description of user data area). Different telegram
lengths can be used for different slave nodes on the bus. The maximum total length of a
telegram is 256 bytes. The LGE is defined as the user data characters (quantity n), address
byte (ADR) and the block check character (BCC). The actual total telegram length will of
course be two bytes longer than the LGE as the STX and LGE bytes are not counted in the
LGE.
Variable length telegrams and fixed length telegrams can both be used. This can be selected
using parameters P2012 and P2013 to define the PZD and PKW lengths. Most common
fixed length applications will use a 4-word (8-byte) PKW area and a 2-word (4-byte) PZD
area giving 12 user data characters. This gives the LGE = 12 + 2 = 14.

ADR
The ADR field is a single byte containing the address of the slave node (e.g. inverter). The
individual bits in the address byte are addressed as follows:

7 6 5 4 3 2 1 0

Special Mirror Broadcast 5 address bits

Bit 5 is the broadcast bit. If it is set to 1, the message is a broadcast message and will be
acted upon by all inverters on the serial link. The node number is not evaluated. The USS
protocol specification requires certain settings in the PKW area, refer to the later example on
using USS broadcast mode.
Bit 6 = 1 indicates a mirror telegram. The node number is evaluated and the addressed slave
returns the telegram unchanged to the master.
Bit 5 = 0 and bit 6 = 0 and bit 7 = 0 means normal data exchange for units. The node number
(bit 0 … bit 4) is evaluated.

BCC
BCC means block check character. It is an exclusive OR (XOR) checksum over all telegram
bytes except the BCC itself.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-25
Functions
8.7 Communication via USS

8.7.2 User data area of USS telegram

Basic USS parameters

General rule: Index[0] for USS on RS485, Index[1] for USS on RS232.

P2010 USS Baudrate [2400 … 115200] baud

P2011 USS Slave Address: [0 … 30]
P2012 USS PZD Length: [0 … 2 … 8] words
P2013 USS PKW Length: [0, 3 (3 words), 4 (4 words), 127 (variable length)]
P2014 USS Telegram Off-Time: [0 … 65535] ms. ‘0’ = no timeout check!
R2015 Received PZD via USS on RS232
P2016 BICO Selection for PZDs to be sent via USS on RS232
R2018 Received PZD via USS on RS485
P2019 BICO Selection for PZDs to be sent via USS on RS485
r2032 Control Word 1 from USS on RS232
r2033 Control Word 2 from USS on RS232
r2034 Control Word 1 from USS on RS485
r2035 Control Word 2 from USS on RS485

User data structure

The user data area of the USS protocol is used for transferring the application data, which
are parameter data (PKW) and process data (PZD).
The application data occupies the bytes within the USS frame (STX, LGE, ADR, BCC). The
size of the application data can be configured by parameters p2013 and p2012. The
following figure shows the structure and order for the parameter data (PKW) and process
data (PZD).

'DWD%\WHV

   ::: p. S S S ::: Q

3URWRFRO'DWD

3.: 3='

3URWRFRO:RUGV

3.: ::: 3.:[ 3=' ::: 3='\

3 3

Figure 8-18 USS Application Data

Control Units CU240S

8-26 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.7 Communication via USS

The length of the PKW channel is determined by parameter P2013, that for the process data
by parameter P2012. If either no PKW or no PZD is required, the corresponding parameters
can be set to zero ("PKW only" or "PZD only" respectively). It is not possible to transmit
"PKW only" and "PZD only" alternatively. If both channels are required they must be
transferred together.

8.7.3 Process data channel (PZD)

Description
In this area of the telegram, process data (PZD) are continually exchanged between the
master and slaves. Dependent of the direction the process data channel contains data for a
request to the USS slaves or for a response to the USS master. In the requests are control
words and setpoints for the slaves and in the responses are status words and actual values
for the master.

67: +6: 67:

5HTXHVW 3=' 3=' 3=' 3=' 3='


WR866VODYH

3

=6: +,: =6:

5HVSRQVH 3=' 3=' 3=' 3='  3='

WR866PDVWHU

3 

3 

Figure 8-19 Process data channel

The number of PZD words in a USS-telegram are determined by parameter P2012, where
the first two words are:
● Control word 1(STW1) and main setpoint (HSW)
● Status word 1 (ZSW1) and actual value (HIW)
If P2012 is greater or equal to 4 the additional control word (STW2) is transferred as the 4th
PZD word (default setting).
The sources of all other PZDs are defined with parameter P2019 for a RS485 interface and
P2016 for a RS232 interface.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-27
Functions
8.7 Communication via USS

8.7.4 Parameter data channel (PKW)

Parameter data area (PKW)

The USS protocol defines for the inverters, the user data structure with which a master can
access the inverter slaves. The PKW (parameter identifier value) telegram section can be
used to monitor and/or change any parameter in the inverter.

PKW mechanism for processing parameters

Using the PKW mechanism parameters can be processed and monitored (write/read) as
described below. The parameter area includes at least 3 words and is set with parameter
P2013. Values for P2013 are the number of PKW words. Possible settings are 0, 3, 4, 127
with 127 for variable length.

3.: $EEUHYLDWLRQV 3.:3DUDPHWHULGHQWLILHUYDOXH

3.( 3:( 3.(3DUDPHWHULGHQWLILHU
,1'
,1',QGH[
VW  QG UGDQGWK 3:(3DUDPHWHUYDOXH
ZRUG ZRUG ZRUG

Figure 8-20 Structure of parameter area (PKW)

Parameter identifier (PKE), 1st word

The parameter identifier (PKE) is always a 16-bit value.

3.:
3.( ,1' 3:(
VW  QG UGDQGWK
ZRUG ZRUG ZRUG

               
630

$. E318

Figure 8-21 PKE structure

● Bits 0 to 10 (bPNU) contain the remainder of the parameter number (value range 1 to
1999). For parameter numbers ≥ 2000 it is necessary to add an offset which is defined
with the high byte bits of IND.
● Bit 11 (SPM) is reserved and always = 0.
● Bits 12 to 15 (AK) contain the request or the response identifier.

Control Units CU240S

8-28 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.7 Communication via USS

The meaning of the request identifier for request telegrams (master → inverter) is shown in
the table below. Request identifiers 11 to 14 are specific to the SINAMICS G120.

Table 8-10 Request identifier (master → inverter)

Request Meaning Response

identifier identifier
positive negative
0 No request 0 7/8
1 Request parameter value 1/2 ↑
2 Modify parameter value (word) 1 |
3 Modify parameter value (double word) 2 |
4 Request descriptive element 1) 3 |
6 Request parameter value (array) 1) 4/5 |
7 Modify parameter value (array, word) 1) 4 |
8 Modify parameter value (array, double word) 1) 5 |
9 Request number of array elements 6 |
11 Modify parameter value (array, double word) and store in EEPROM 5 |
1)

12 Modify parameter value (array, word) and store in EEPROM 1) 4 |

13 Modify parameter value (double word) and store in EEPROM 2 ↓
14 Modify parameter value (word) and store in EEPROM 1 7/8
1) For these tasks, to make them completely clear, an additional value is required, which is located in
IDX
The meaning of the response identifier for response telegrams (inverter → master) is shown
in the table below. The request identifier will determine which response identifiers are
possible.

Table 8-11 Response identifier (inverter → master)

Response identifier Meaning

0 No response
1 Transfer parameter value (word)
2 Transfer parameter value (double word)
3 Transfer descriptive element 1)
4 Transfer parameter value (array word) 1)
5 Transfer parameter value (array double word) 1)
6 Transfer number of array elements
7 Cannot process request, task cannot be executed (with error number)
8 No master control status / no parameter change rights for PKW interface
1) For these tasks, to make them completely clear, an additional value is required, which is located in
IDX

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-29
Functions
8.7 Communication via USS

If the response identifier is 7 (cannot process request), then one of the fault numbers listed in
the next table will be stored in parameter value 2 (PWE2).

Table 8-12 Fault numbers for "Cannot process request" response

No. Meaning
0 Illegal parameter number (PNU) Parameter does not exist
1 Parameter value cannot be modified Parameter is a read-only parameter
2 Minimum/maximum not reached/exceeded –
3 Faulty subindex –
4 No array Single parameter has been accessed
with array request and subindex > 0
5 Parameter type is wrong / incorrect data type Mix-up between word and double
word
6 Setting not allowed (resetting only) –
7 Descriptive element cannot be modified Description can never be modified
11 No status as master control Modification request without status as
master control (see P0927)
12 Key word missing –
15 Text array is not available –
17 Request cannot be processed due to operating Current inverter status is not
state compatible with the received request
20 Change request for a value which is between the There are other reasons why the
lower an the upper limit change request is not allowed; it is a
parameter with defined single values
101 Parameter number currently deactivated Dependent on inverter status
102 Response does not fit into buffer Dependent on the number of PKW
and the maximum net data length in
the drive
104 Illegal parameter value Parameter permits only certain values
106 Request not implemented / Task not supported After request identifier 5, 10, 15
109 PKW request access timeout or number of retries
is exceeded or wait for response from CPU side.
200/201 Modified minimum/maximum not Minimum/maximum can be further
reached/exceeded limited in operation
204 Available access authorization does not cover –
modification of parameters

Control Units CU240S

8-30 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.7 Communication via USS

Parameter index (IND) 2nd word

The parameter index (IND) is always a 16-bit value.

3.:
3.( ,1' 3:(
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ZRUG ZRUG ZRUG

               
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Figure 8-22 IND structure

● The low byte of IND is used for the parameter index IDX and can have values between 0
and 255. The IND low byte IDX = 255 has a special meaning. For this index value, the
task is referred to the complete array or the complete parameter description.
● Bits 8 and 9 are always 0.
● Bits 10 to 15 are interpreted as a page index to determine the full parameter number. The
bPNU (bits 0 to 10 of PKE) is limited to values between 0 and 1999. The parameter
number is a concatenation of bPNU and a multiplier determined by the 6 higher bits of
IND. It is defined als follows:
,1'

               
D G F E I H

The full PNU is derived as follows: PNU = 2000 * (a + b * 2 + c * 4 + d * 8 + e * 16 + f * 32) +

bPNU

Table 8-13 Regulation for setting the PNU

Parameter range Page index Bit Hex value + bPNU

a d c b f e 9 8
0000 – 1999 0 0 0 0 0 0 0 0 0 0 – 7CF
2000 – 3999 1 0 0 0 0 0 0 0 0x80 0 – 7CF
4000 – 5999 0 0 0 1 0 0 0 0 0x10 0 – 7CF
6000 – 7999 1 0 0 1 0 0 0 0 0x90 0 – 7CF
8000 – 9999 0 0 1 0 0 0 0 0 0x20 0 – 7CF
…
60000 – 61999 0 1 1 1 0 1 0 0 0x74 0 – 7CF

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-31
Functions
8.7 Communication via USS

Table 8-14 Example coding for parameter no. in PKE and IND for P8820, Index 16

PKE IND
decimal xx 820 8000 16
hex xx 334 20 10

Parameter value (PWE)

The number of PWEs can vary. For 16 bit values one PWE is required. If 32 bit values are
exchanged, two PWEs are required.

Note
Data types U8 will be transferred as U16 with the upper byte zero. Arrays of U8 will therefore
require one PWE per index.

A PKW area for 3 words is a typical data frame for exchanging 16 bit data or alarm
messages. The mode with a fixed PZD length of 3 is used with p2013 = 3.
A PKW area for 4 words is a typical data frame for exchanging 32 bit data variables and
requires p2013 = 4.
A PKW area for a flexible PZD length is used with p2013 = 127. The length for telegrams
between master and slave can have a different number of PWEs.
If the length of PKW is fixed (p2013 = 3 or 4), then the Master must always correctly send
either 3 or 4 words in the PKW area (if not, the slave will not respond to the telegram). The
slave response PKW will be either 3 or 4 words as well. If a fixed length is used, this should
be 4, as 3 would not be sufficient to support many of the parameters (i.e. double words). For
variable length of PKW (p2013 = 127) the Master sends only the necessary number of words
for the task in the PKW area. The length of the response telegram will also only be as long
as necessary.

Control Units CU240S

8-32 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.7 Communication via USS

Rules for processing requests/responses

● A request or a response can only ever refer to one parameter.
● The master must repeat a request continuously until it has received the appropriate
response.
● The master detects the response to a request it has sent by
– evaluating the response identifier,
– evaluating the parameter number PNU,
– evaluating the parameter index IND if necessary, or
– evaluating the parameter value PWE if necessary.
● The complete request must be sent in one telegram. Request telegrams cannot be split.
The same applies to responses.
● In the case of response telegrams which contain parameter values, the drive always
returns the momentary parameter value when repeating response telegrams.
● If no information needs to be fetched from the PKW interface in cyclical operation (only
PZD data are relevant), then the "No request" request telegram must be issued.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-33
Functions
8.7 Communication via USS

8.7.5 Timeouts and other errors

Telegram Timeouts
For the timeout monitoring, the character run time is important:

Table 8-15 Character run time

Baudrate in bit/s Transfer time per character (= 11 bit) Transfer time per bit Character run time
9600 1.146 ms 104.170 us 1.146 ms
19200 0.573 ms 52.084 us 0.573 ms
38400 0.286 ms 26.042 us 0.286 ms
187500 0.059 ms 5.340 us 0.059 ms
The following figure shows the meaning of the "residual run time":

Residual run time 50 % of the compressed

(compressed telegram) WHOHJUDPUHVLGXDOUXQWLPH

67; /*( $'5   ::: Q %&&

67; /*( $'5   ::: Q %&&

&KDUDFWHUGHOD\WLPH &KDUDFWHUUXQWLPH

0D[LPXPWHOHJUDPUHVLGXDOUXQWLPH

Figure 8-23 Residual Run Time and Character Delay Time

The character delay time can be zero and must be smaller than the start delay!
The following figure shows the various delays and transmission times:

67; /*( $'5  ::: Q %&& 67; /*( : : :

0DVWHU5HTXHVW 6ODYH5HVSRQVH 0DVWHU5HTXHVW

: : : %&& 67; /*( $'5  ::: Q %&&

6WDUW'HOD\ 5HVSRQVH'HOD\ 6WDUW'HOD\

Figure 8-24 Start Delay and Response Delay

Control Units CU240S

8-34 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.7 Communication via USS

Character delay time timeout between characters and must be smaller than 2 time the
character run time but can be zero
Start delay timeout between USS messages. Must be > 2 * character run time
Response delay Processing time of the slave. Must be < 20 ms, but larger than the
start delay!
Residual run time < 1.5 * (n + 3) * character run time (where n = number of data bytes)
"Slave is the sum of "Start delay", "Response delay" and "Residual run
Transmitting"/ time"
"Master
Transmitting"
The master must check the following times:

• "Response delay" = reaction time of slave to USS request

• "Residual run time" = transmission time of response telegram sent by slave
The slave must check the following times:

• "Start delay" = timeout between USS messages

• "Residual run time" = transmission time of request telegram coming from master

0DVWHU5HTXHVW

67; /*( $'5  ::: Q %&& 6ODYH5HVSRQVH

5HVSRQVH'HOD\

67; /*( $'5  :::

::: %&&
6WDUW'HOD\

  FUW

 Q FUW

  FUW   FUW

Figure 8-25 Timeout Checks on USS Slave

The timeout margins that are verified on the USS slave are shown in the figure above. "crt"
stands for "character run time". The factor "1.5" is the maximum margin. The "start delay"
and the minimum "response delay" are fixed minimum values in software. The "residual run
times" are monitoring values that cause a timeout if they are exceeded by the character
reception.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-35
Functions
8.7 Communication via USS

Process Timeouts
Parameter P2014 determines the timeout in ms. A value of zero disables the timeout check.
Parameter P2014 checks the cyclic refresh of Bit10 in control word 1.
When USS is configured as command source of the drive and P2014 is not zero, Bit10 of the
received control word 1 is examined. If the bit is not set, an internal timeout counter is
incremented. If the threshold of p2014 is reached, a process timeout fault is set by the drive.

Other errors
P2025 = USS rejected
P2026 = USS character frame error
P2027 = USS overrun error
P2028 = USS parity error
P2029 = USS start not identified
P2030 = USS BCC error
P2031 = USS length error

Control Units CU240S

8-36 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.8 Fixed frequencies

8.8 Fixed frequencies

Data

Number: 15
Parameter range: P1001 … P1025
Warnings: -
Faults: -
Function chart number: FP3200, FP3210

Description
The fixed frequency functionality allows to enter a setpoint to the drive. This is an alternative
option to enter a setpoint with using the analog inputs, the serial communication interfaces,
the JOG function or the motorized potentiometer. The fixed frequencies are defined using
parameters P1001 … P1015 and selected and combined using binector inputs P1020 …
P1023. The effective fixed frequency setpoint is available through connector output r1024. If
this is to be used as setpoint source, then parameter P1000 should be modified or connector
output r1024 should be connected to the main setpoint P1070 or supplementary setpoint
P1075.
There are two modes to select fixed frequencies, which are set via the parameter P1016:
● Direct selection (P1016 = 1)
● Binary-coded selection (P1016 = 2)
The fixed frequency status bit r1025 (binector output) allows to combine the two selection
modes for fixed frequencies with an ON command. For this, P0840 should be set to 1025.
Please note that the meaning of P0840 may change with using the 2-/3-wire control
functionality.

Direct selection (P1016 = 1)

In this particular mode, a control signal directly selects the fixed frequency. This control
signal is entered using the binector inputs P1020 … P1023. For this selection a permanent
signal at the parameters P1020 … P1023 is necessary. If several fixed frequencies are
simultaneously active, then the selected frequencies are added.
The control signal for selection of the fixed frequencies can be any binary output (BO)
parameter such as a serial communication interface or in most cases a digital input. When
selecting fixed frequencies with digital inputs, two connection methods are available:
● Standard method
● BICO method

Note
The standard method has priority over the BICO method.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-37
Functions
8.8 Fixed frequencies

Examples
The fixed frequencies are selected via the digital inputs 4 … 6 and the analog/digital input
AI0.
● Standard method:
P0704 = 15, P0705 = 16, P0706 = 17 (default) and P0712 = 18, P1023 = 722.11
Each digital input (P0701 and the following) can be connected to each fixed frequency
selector input (P1020 … P1023) with the settings 15, 16, 17 or 18. The different settings
can only be chosen once. If the same setting of a digital input is chosen for more than
one digital input, then only the last setting is valid and the previous digital input setting is
reset to 0.
● BICO method:
P0704 … P0706, P0712 = 99, P1020 … P1022 = 722.3 … 722.5, P1023 = 722.11
(example: DI3 connects to selector P1020 → P0704 = 99, P1023 = 722.3)
Each digital input (P0701 and the following) can be BICO connected to each fixed
frequency selector input (P1020 … P1023). If the same setting of a digital input is chosen
for more than one digital input, then only the last setting is valid and the previous digital
input setting is reset to 0.

Table 8-16 Example of direct selection using digital inputs

FF number Frequency P1023 P1022 P1021 P1020

FF0 0 Hz 0 0 0 0
FF1 P1001 0 0 0 1
FF2 P1002 0 0 1 0
FF3 P1003 0 1 0 0
FF4 P1004 1 0 0 0
FF1+FF2 0 0 1 1
FF1+FF2+FF3 0 1 1 1
FF1+FF2+FF3+FF4 1 1 1 1

Control Units CU240S

8-38 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.8 Fixed frequencies

P1016 = 1
P1020
DI3 r0722 722:3
P0704 = 15 or P0704 = 99

...
...
P1022

...
DI5 r0722 722:5
P0706 = 17 or P0706 = 99 1 r1025
P1023
AI0 r0722 722:11
P0712 = 18 or P0712 = 99
...
0 +
r1024
P1001

...
0 +
P1003
0
P1004

Figure 8-26 Example of direct selection of fixed frequencies

Binary-coded selection (P1016 = 2)

Using this technique up to 16 fixed frequencies can be selected using four control signals.
The fixed frequencies are indirectly selected using the binary coding. The connection
methods to the fixed frequency selector inputs (P1020 … P1023) are as for the direct
selection mode.
Example
● Standard method:
P0704 = 15, P0705 = 16, P0706 = 17 and P0712 = 18, P1023 = 722.11
● BICO method:
P0704 … P0706, P0712 = 99, P1020 … P1022 = 722.3 … 722.5, P1023 = 722.11

Table 8-17 Example of binary-coding using digital inputs

FF number Frequency P1023 P1022 P1021 P1020

FF0 0 Hz 0 0 0 0
FF1 P1001 0 0 0 1
FF2 P1002 0 0 1 0
FF3 P1003 0 0 1 1
FF4 P1004 0 1 0 0
… … … … … …
FF14 P1014 1 1 1 0
FF15 P1015 1 1 1 1

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-39
Functions
8.8 Fixed frequencies

P1016 = 2
P1020
DI3 r0722 722:3
P0704 = 15 or P0704 = 99

...
...

P1022

...
DI5 r0722 722:5
P0706 = 17 or P0706 = 99 1 r1025
P1023
AI0 r0722 722:11
...
P0712 = 18 or P0712 = 99
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  r1024


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Figure 8-27 Example of binary-coded selection of fixed frequencies

Control Units CU240S

8-40 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.9 2-/3-wire control

8.9 2-/3-wire control

Data

Parameter range: P0727

P0701 … P0713
P0840, P0842, P1113
Warnings: -
Faults: -
Function chart number: -

Description

Note
Automatic restart function
When a 2-/3-wire control methods is selected, the automatic restart function (P1210) is
disabled. If the automatic restarted function is required, the user must specifically enable this
function. For further details, please see the Parameter List.

The different types of 2-/3-wire control are enabled using parameter P0727 and selecting
one of the following options:

Default value
● P0727 = 0: Siemens standard control (ON/OFF1, REV).

Other settings
● P0727 = 1: 2-wire control (ON_FWD, ON_REV)
● P0727 = 2: 3-wire control (FWDP, REVP, STOP)
● P0727 = 3: 3-wire control (ON_PULSE, REV, OFF1/HOLD)
When any of the control functions are selected using P0727, the settings for the digital inputs
(P0701 … and P0712, P0713 for AI used as DI) are redefined as shown in the table below.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-41
Functions
8.9 2-/3-wire control

Table 8-18 Redefined digital inputs

Settings P0727 = 0 P0727 = 1 P0727 = 2 P0727 = 3

P0701 … Siemens Standard 2-wire control 3-wire control 3-wire control
(P0712, P0713)
1 ON/OFF1 ON_FWD STOP ON_PULSE
2 ON_REV/OFF1 ON_REV FWDP OFF1/HOLD
12 REV REV REVP REV
"P" denotes "Pulse"; "FWD" denotes "Forward"; "REV" denotes "Reverse"
Each of the control methods shown in the table above will be explained individually.

BICO connections
The different 2-/3-wire control methods can also be accomplished using BICO connections.
A summary is given in the table below.

Table 8-19 BICO Connections

Functions of BICO P0727 = 0 P0727 = 1 P0727 = 2 P0727 = 3

parameter Siemens Standard 2-wire control 3-wire control 3-wire control
P0840 ON/OFF1 ON_FWD STOP ON_PULSE
P0842 ON_REV/OFF1 ON_REV FWDP OFF1/HOLD
P1113 REV REV REVP REV
"P" denotes "Pulse"; "FWD" denotes "Forward"; "REV" denotes "Reverse"

8.9.1 Siemens standard control (P0727 = 0)

Description
With P0727 = 0 there are two possibilities of control available using the following signals
1. ON/OFF1 and REV.
2. ON/OFF1 and ON_REV/OFF1.

Control Units CU240S

8-42 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.9 2-/3-wire control

ON/OFF1 and REV

This method allows the inverter to be started and stopped using the ON/OFF1 command and
the direction of the inverter changed using the REV command. These commands can be
assigned to any of the digital inputs through parameters P0701 … P0709 (and P0712,
P0713 for AI used as DI) or BICO connections.
The REV commands can be given at any time, independent of the frequency output of the
inverter.

Function
On receiving an ON/OFF1 command the inverter will run the motor in a forward direction and
ramp-up the motor to the frequency setpoint.
When a REV command is issued, the inverter will ramp-down the frequency through 0 Hz
and run the motor in the reverse direction. When the REV command is removed the inverter
will ramp-up through 0 Hz and run in a forward direction until the frequency setpoint is reach.
When the ON/OFF1 command is removed, the inverter will stop the motor by performing an
OFF1.
The REV command initiated by itself cannot start the motor.

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Figure 8-28 Siemens standard control using ON/OFF1 and REV

ON/OFF1 and ON_REV/OFF1

This method allows the inverter to run the motor in a forward direction (run right) using the
ON/OFF1 command and in the opposite direction (run left) using the ON_REV/OFF1.
However, for a direction reversal the drive will first have to decelerate with OFF1 and when
reaching 0 Hz the reverse signal can be applied.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-43
Functions
8.9 2-/3-wire control

Function
The ramp down phase can be interrupted by start command in the same direction: if the
drive was operating in forward and OFF1 was applied, an ON/OFF1 will work correctly and
accelerate again the drive up to the setpoint speed. The same is valid for reverse and
ON_REV/OFF1
Giving a start command for the opposite direction of which the inverter frequency output is
ramping down, the drive ignores the new setting and the drive will ramp down to 0 Hz and
then remain at standstill.
Without any control signal enabled the drive will ramp down to a stop and remain at
standstill.

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Figure 8-29 Siemens standard control using ON/OFF1 and ON_REV/OFF1

8.9.2 2-wire control (P0727 = 1)

Description
This method uses two maintained signals, ON_FWD and ON_REV which start/stop the
inverter and determine the direction of the motor.
The advantage of this method of control is that ON_FWD and ON_REV can be switched at
any time, independently of the setpoint or frequency output or direction of rotation, and there
is no requirement of the motor to ramp-down to 0 Hz before the command is performed.

Control Units CU240S

8-44 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.9 2-/3-wire control

Function
With ON_FWD closed and maintained closed the drive is ON and runs in forward direction.
Applying only ON_REV (and keeping the contact closed) the drive is ON and runs in reverse
direction.
If both signals are however enabled (contacts are closed) the drive will perform an OFF1 and
ramp down to a stop.
If both signals are disabled the drive is in OFF1 state.

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Figure 8-30 2-wire control using ON_FWD and ON_REV

8.9.3 3-wire control (P0727 = 2)

Description
This method uses three commands to control the operation of the motor:
1. STOP: Causes on OFF1 command to be performed by the inverter.
2. FWDP: Causes the motor to run in a forward direction (run right).
3. REVP: Causes the motor to run in the reverse direction (run left).

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-45
Functions
8.9 2-/3-wire control

Function
The STOP signal uses negative logic: Opening the contact or maintaining it open causes an
OFF1 condition and the drive stops. The STOP contact will need to be maintained closed to
start and run the inverter.
Then a momentary closure (positive edge) of the FWDP or REVP contact latches and starts
the inverter.
A momentary closure (positive edge) of the FWDP contact will set the forward direction.
A momentary closure of the REVP contact will change to the reverse direction.
Closing FWDP and REVP will cause a Stop (OFF1).
The ramp down can be interrupted by a single new pulse FWDP or REVP.
A momentary closure of the FWDP or REVP contacts while the drive is operating in the
respective direction will not cause any change.
Only by opening the STOP contact the drive will switch off regularly, apart from the special
case that both signals FWDP and REVP are present.

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Figure 8-31 3-wire control using FWDP, REVP and STOP

Control Units CU240S

8-46 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.9 2-/3-wire control

8.9.4 3-wire control (P0727 = 3)

Description
There are three signals associated with this function:

OFF1/HOLD: Being maintained closed the opening of the contact will switch the
inverter OFF and cause a ramp down to 0 Hz.
ON_PULSE: This will run the motor in a forward direction (run right).
REV: This will change the direction of the motor to reverse (run left).

Function
The switch OFF1/HOLD uses negative logic: the contact will need to be maintained closed in
order to switch the inverter ON or keep it running.
A momentary closure (positive edge) of the ON_PULSE switch latches and starts the inverter
if it was OFF before.
The direction can be determined and changed any time using the REV signal.
Opening or closing the ON_PULSE switch while the drive runs has no effect.
Only enabling (i.e. Opening) OFF1/HOLD will unlatch the run-state and then stop the
inverter.

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Figure 8-32 3-wire control using ON_PULSE, OFF1/HOLD and REV

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-47
Functions
8.10 Motorized potentiometer (MOP)

8.10 Motorized potentiometer (MOP)

Data

Parameter range: P1031 – r1050

Warnings: -
Faults: -
Function chart number: FP3100

Description
This function emulates an electromechanical potentiometer to enter setpoints. The motorized
potentiometer (MOP) value is adjusted using the "Raise" and "Lower control signal" which is
selected using BICO parameters P1035 and P1036. The value which has been set is
available through connector output r1050 so that it can be utilized and connected.


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The behavior of the MOP also depends on the duration of the up and down command:
● P1035 (P1036) = 1 for < 1 s :
Frequency changes in steps of 0.1 Hz.
● P1035 (P1036) = 1 for > 1 s :
Frequency ramps up (down) with the time of P1120 (P1121) but not faster than 2 s.

Control Units CU240S

8-48 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.10 Motorized potentiometer (MOP)

The MOP functionality can be selected using the operator panel, digital inputs or the serial
interface. Parameterization is also possible directly using BICO parameters P1035 and
P1036 as well as parameter P0700. In this case, for a value assigned to P0700, the BICO
parameter is appropriately modified.

Example

Command source via "USS on RS232" (using the PC connection kit on the option port)
Standard method P0700 = 4
BICO method P1035 = 2032.13
P1036 = 2032.14
…
(for a complete list refer to Parameter List P0700)
If the motorized potentiometer is to be used as a setpoint source, then parameter P1000
should be modified or the BICO parameter r1050 should be connected to the main setpoint
P1070 or supplementary setpoint P1075. When parameter P1000 is modified, this implicitly
changes BICO parameters P1070, P1075.

Example

Setpoint via the motorized potentiometer (MOP)

Standard method P1000 = 1
BICO method P1070 = 1050
P1075 = 0
The MOP is configured using the following parameters and has the modes of operation as
shown in the table below.
● Limits using the minimum frequency P1080 or maximum frequency P1082
● Ramp-up/ramp-down time P1120 or P1121
● Inhibits MOP reversing function P1032
● Saves the MOP setpoint P1031
● MOP setpoint P1040

Table 8-20 MOP modes of operation

Motorized potentiometer Function

Lower Raise
0 0 Setpoint is frozen
0 1 Raise setpoint
1 0 Lower setpoint
1 1 Setpoint is frozen

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-49
Functions
8.11 JOG

8.11 JOG

Data

Parameter range: P1055 … P1061

Warnings: A0923
Faults: -
Function chart number: FP5000

Description
The JOG function is used as follows:
● To check the functionality of the motor and inverter after commissioning has been
completed (the first traversing motion, checking the direction of rotation, etc.)
● Positioning a motor or a motor load into a specific position
● Traversing a motor, e.g. after a program has been interrupted
The motor is traversed using this function by entering fixed frequencies P1058, P1059. The
JOG mode can be selected using the operator panel, digital inputs or the serial interface. An
ON/OFF command is not used to move the motor, but instead when the "JOG keys" are
pressed movement takes place. These "JOG keys" are selected using the BICO parameters
P1055 and P1056. The JOG function can be disabled via P1057.

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Control Units CU240S

8-50 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.11 JOG

Pressing the appropriate key accelerates the motor to the frequency in P1058 (JOG right) or
P1059 (JOG left) at the ramp rate set in P1060. When the key is released, the motor stops,
decelerating at the rate set in P1061. If JOG right and JOG left signals are given at the same
time, there is no reaction, and a warning A0923 is raised. Internal BICO connections may
also be used to select other settings and control methods.

Example

Command source via "USS RS232" interface (using the PC connection kit on the option port)
Standard method P0700 = 4
BICO method P1055 = 2032.8
P1056 = 2032.9
…
(for a complete list refer to Parameter List P0700)

Note
The JOG fuction as used in the SINAMICS G120 inverter does not correspond to the
definition in PROFIdrive profile.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-51
Functions
8.12 PID Controller

8.12 PID Controller

Data

Parameter range: P2200, P2201 … P2355

Warnings: A0936
Faults: F0221, F0222
Function chart number: FP3300, FP3400, FP5100
Features:
- cycle time: 8 ms

Description
The SINAMICS G120 has an integrated technology controller (PID controller, enabled
through P2200). This can be used to process basic higher-level closed-loop control
functions. These typically include:
● Closed-loop pressure control for extruders
● Closed-loop water level control for pump motors
● Closed-loop temperature control for fan motors
● Closed-loop dancer roll position control for winder applications
● And similar control tasks
The technology controller setpoints and actual values can be entered using the PID
motorized potentiometer (PID-MOP), PID fixed setpoint (PID-FF), analog inputs (AI) or
through the serial interface as shown in the figure below. The appropriate parameterization
of the BICO parameter defines which setpoints or actual values are to be used.

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Control Units CU240S

8-52 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.12 PID Controller

Example

PID controller enable and PID setpoint input via PID fixed frequencies and PID actual value via the
analog input
Permanent PID enable P2200 = 1.0
Setpoint input via PID-FF P2253 = 2224
Actual value input via analog input AI P2264 = 755
Setpoint input via PID P2251 = 0
The supplementary (additional) setpoint is added to the main setpoint (PID-SUM) and the
sum is fed to the setpoint-actual value summation point through the PID ramp-function
generator (PID-RFG). The source of the supplementary setpoint (BICO parameter P2254),
the ramp-up/ramp-down times of the PID ramp-function generator (P2257, P2258) as well as
the filter time (P2261) can be adapted to the particular application by appropriately
parameterizing the corresponding parameters.
Similar to the PID setpoint branch, the actual value branch of the technological controller has
a filter (PID-PT1) which can be set using parameter P2265. In addition to the smoothing, the
actual value can be modified using a scaling unit (PID-SCL).
The technological controller can be parameterized as either P, I, PI or PID controller using
parameters P2280, P2285 or P2274.

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For specific applications, the PID output quantity can be limited to defined values. This can
be achieved using the fixed limits - P2291 and P2292. In order to prevent the PID controller
output exercising large steps at power-on, these PID output limits are ramped-up with ramp
time P2293 from 0 to the corresponding value P2291 (upper limit for the PID output) and
P2292 (lower limit for the PID output). As soon as these limits have been reached, the
dynamic response of the PID controller is no longer limited by this ramp-up/ramp-down time
(P2293).

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-53
Functions
8.12 PID Controller

8.12.1 PID motorized potentiometer

Data

Parameter range: P2231 … r2250

Warnings: -
Faults: -
Function chart number: FP3400

Description
The PID controller has a PID motorized potentiometer (PID-MOP) which can be separately
adjusted. The functionality is identical with the motorized potentiometer, whereby the PID
parameters are emulated in the range from P2231 … r2250.

Table 8-21 Correspondence between the parameters

PID motorized potentiometer Motorized potentiometer

P2231[3] Setpoint memory of PID-MOP P1031[3] Setpoint memory of the MOP
P2232 Inhibit rev. direct. of PID-MOP P1032 Inhibit reverse direction of MOP
P2235[3] BI: Enable PID-MOP (UP-CMD) P1035[3] BI: Enable MOP (UP command)
P2236[3] BI: Enable PID-MOP (DOWN-CMD) P1036[3] BI: Enable MOP (DOWN command)
P2240[3] Setpoint of PID-MOP P1040[3] Setpoint of the MOP
r2250 CO:Output setpoint of PID-MOP r1050 CO: Act. output freq. of the MOP
For more detail refer to Section "Motorized potentiometer (MOP)" in this Chapter.

8.12.2 PID fixed setpoint

Data

Quantity: 15
Parameter range: P2201 … P2225
Warnings: -
Faults : -
Function chart number: FP3300, FP3310

Control Units CU240S

8-54 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.12 PID Controller

Description
Similar to the fixed frequencies, the PID controller has separate programmable PID fixed
setpoints (PID-FF). The values are defined using parameters P2201 … P2215 and are
selected and combined using binector inputs P2220 … P2223. The selected PID fixed
setpoint is available using connector output r2224 where it can be further processed (e.g. as
PID main setpoint → P2253 = 2224).
Two modes are available to select the PID fixed setpoints, similar to the fixed frequencies.
They are set via parameter P2216:
● Direct selection (P2216 = 1)
● Binary-coded selection (P2216 = 2)
The fixed frequency status bit r2225 (binector output) allows to combine the two selection
modes for fixed frequencies with an ON command. For this, P0840 should be set to 2225.
Please note that the meaning of P0840 may change with using the 2/3 wire functionality.
All logical connections are like the connections with fixed frequencies and for each selection
mode there are the two connection methods:
● Standard method
● BICO method

Note
The standard method has priority over the BICO method.

Direct selection (P2216 = 1)

Table 8-22 Example of direct selection using digital inputs

FF number Frequency P2223 P2222 P2221 P2220

PID-FF0 0 Hz 0 0 0 0
PID-FF1 P2201 0 0 0 1
PID-FF2 P2202 0 0 1 0
PID-FF3 P2203 0 1 0 0
PID-FF4 P2204 1 0 0 0
PID-(FF1+FF2) 0 0 1 1
PID-(FF1+FF2+FF3) 0 1 1 1
PID-(FF1+FF2+FF3+FF4) 1 1 1 1

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-55
Functions
8.12 PID Controller

P2216 = 1
P2220
DI3 r0722 722:3
P0704 = 15 or P0704 = 99
1

...
r2225
...

...
0 +
r2224
P2201

...
Figure 8-37 Directly selected PID fixed setpoint using DI3

Binary-coded selection (P2216 = 2)

Table 8-23 Example of binary-coding using digital inputs

FF number Frequency P2223 P2222 P2221 P2220

PID-FF0 0 Hz 0 0 0 0
PID-FF1 P2201 0 0 0 1
PID-FF2 P2202 0 0 1 0
… … … … … …
PID-FF14 P2214 1 1 1 0
PID-FF15 P2215 1 1 1 1

8.12.3 PID dancer roll control

Data

Parameter range: P1070, P1075, P1120, P1121,

P2200, P2251 … P2285
Warnings: -
Fault: -
Function chart number: -

Description
For various continuous production processes, for example, in the paper and pulp industry or
in the manufacture of cables, it is necessary to control (closed-loop) the velocity of stations
along the production process so that the continuous material web is not subject to any
unwanted tension levels. It is important that no folds or creases are formed. For applications
such as these, it is practical to provide a type of material buffer in the form of a loop with a
defined tension. This provides a de-coupling between the individual inverter locations. This
loop represents the difference between the material fed-in and that fed-out and therefore
indicates the process quality.

Control Units CU240S

8-56 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.12 PID Controller

Using the PID dancer roll control, with SINAMICS G120 it is possible to ensure that
continuous material webs have a constant tension.

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Figure 8-38 PID dancer roll control

The velocity v1 is assumed to be an independent disturbance; the input velocity v2 should be

controlled using motor rolls A2 so that the length x2 of the loop corresponds, as far as
possible, to the setpoint.

Note
When selecting the closed-loop dancer roll control it should be noted that neither PID-MOP
nor PID-FF should be used - but instead the MOP (motorized potentiometer) or the FF (fixed
frequencies).

The structure and important parameters for the PID dancer roll control are shown below.
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Figure 8-39 Structure of the closed-loop PID-dancer roll control

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-57
Functions
8.12 PID Controller

Table 8-24 Important parameters for PID dancer roll control

Parameter Parameter text Setting Meaning

P1070 CI: Main setpoint 1024 Fixed setpoint (FF)
1050 MOP
755.0 Analog input 0
2015.1 USS on RS232
2018.1 USS on RS485
2050.1 Fieldbus
P2200 BI: Enable PID controller 1.0 PID controller always active
722.x Digital input x
P2251 PID mode 1 PID as trim
P2253 CI: PID setpoint 1024 Fixed setpoint (FF)
1050 MOP
755.0 Analog input 0
2015.1 USS on RS232
2018.1 USS on RS485
2050.1 Fieldbus
P2264 CI: PID feedback 755.0 Analog input 0
755.1 Analog input 1

Control Units CU240S

8-58 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.13 Setpoint channel

8.13 Setpoint channel

Description
The setpoint channel (see figure below) forms the coupling element between the setpoint
source and the closed-loop motor control. The SINAMICS G120 inverter has a special
characteristic which allows the setpoint to be entered simultaneously from two setpoint
sources. The generation and subsequent modification (influencing the direction, suppression
frequency, up/down ramp) of the complete setpoint is carried-out in the setpoint channel.

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Figure 8-40 Setpoint channel

8.13.1 Summation and modification of frequency setpoint

Data

Parameter range: P1070 … r1114

Warnings: -
Fault: -
Function chart number: FP5000, FP5200

Description
For applications where the control quantities are generated from central control systems, fine
tuning is often required locally on-site (correction quantity). For SINAMICS G120, this can be
elegantly realized using the summation point where the main and supplementary (additional)
setpoints are added in the setpoint channel. In this case, both quantities are simultaneously
read-in through two separate or one setpoint source and summed in the setpoint channel.
Depending on external circumstances, the supplementary setpoint can be dynamically
disconnected or switched-in to the summation point (see figure below). This functionality can
be used to advantage, especially for discontinuous processes.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-59
Functions
8.13 Setpoint channel

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Figure 8-41 Summation

SINAMICS G120 has the following possibilities to select the setpoint source:
1. P1000 – selecting the frequency setpoint source
2. BICO parameterization
– P1070 CI: Main setpoint
– P1075 CI: Additional setpoint
Further, the main setpoint as well as the supplementary (additional) setpoint can be scaled
independently of one another. In this case, for example, a user can simply implement an
override function using the appropriate parameterization.
A scan sequence is generally associated with a forwards and a backwards motion. When
selecting the reversing functionality, after reaching the end position, a direction of rotation
reversal can be initiated in the setpoint channel (see figure below).
On the other hand, if a direction of rotation reversal or a negative frequency setpoint is to be
prevented from being entered using the setpoint channel, then this can be inhibited using
BICO parameter P1110.

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Figure 8-42 Modifying the frequency setpoint

Motors can have one or several resonance points in the range from 0 Hz up to the reference
frequency. These resonance points result in oscillations which, under worst case conditions,
can damage the motor load. Using skip frequencies, SINAMICS G120 allows these resonant
frequencies to be passed through as quickly as possible. This means that the skip
frequencies increase the availability of the motor load over the long term.

Control Units CU240S

8-60 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.13 Setpoint channel

8.13.2 Ramp-function generator

Data

Parameter range: P1120, P1121

r1119, r1170
P1130 … P1142
Warnings: -
Faults: -
Function chart number: FP5000, FP5300

Description
The ramp-function generator (RFG) is used to limit the acceleration when the setpoint
changes according to a step function. This therefore helps to reduce the stressing on the
mechanical system of the machine. An acceleration ramp and a braking ramp can be set
independently of one another using the ramp-up time P1120 and the ramp-down time
P1121. This allows a controlled transition when the setpoint is changed (see figure below).

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2 2

P1130+ P1131
IRU > P1120
2 P1130 + P1131 f 2 - f1 P1132 + P1133 f 2 - f1
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> P1121
2
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IRU ≤ P1120
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t up = + P1120⋅ t down = + P1121⋅
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≤ P1121
2

Figure 8-43 Ramp-function generator

In order to avoid torque surges at the transitions (constant velocity phase ←→

accelerating/braking phase), additional rounding-off times P1130 … P1133 can be

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-61
Functions
8.13 Setpoint channel

programmed. This is especially important for applications (e.g. transporting or pumping

liquids or for cranes) which require an especially "soft", jerk-free acceleration and braking.
If the OFF1 command is initiated while the motor is accelerating, then rounding-off can be
activated or deactivated using parameter P1134 (see figure below). These rounding-off times
are defined using parameters P1132 and P1133.

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Figure 8-44 Rounding-off after an OFF1 command

In addition to the rounding-off times, the ramp-function generator can be influenced using
external signals. The ramp-function generator provides the following functionality using BICO
parameters P1140, P1141 and P1142 (see table below).
The ramp-function generator itself is enabled after the pulses have been enabled (inverter
enable) and after the excitation time has expired (P0346). After limiting to the maximum
speeds for the positive and negative directions of rotation (ｱP1082 or 0 Hz for the direction of
rotation inhibit) the setpoint speed for the control is obtained (r1170).
While the V/f characteristic operates up to 650 Hz, the control (vector mode) is limited to a
maximum frequency of 200 Hz (r1084).

Control Units CU240S

8-62 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.13 Setpoint channel

Table 8-25 BICO parameters for ramp-function generator

Parameter Description
P1140 BI: RFG enable The ramp-function generator output is set to 0 if the binary signal
= 0.
P1141 BI: RFG start The ramp-function generator output keeps its actual value if the
binary signal = 0.
P1142 BI: RFG enable setpoint If the binary signal = 0, then the ramp-function generator input is
set to 0 and the output is reduced to 0 through the ramp-function
generator ramp.

Note
The maximum frequency of the setpoint channel is set using parameter P1080.
In V/f mode the maximum frequency is 650 Hz.
In vector mode the maximum frequency is 200 Hz (r1084).

8.13.3 OFF/braking functions

Data

Parameter range: P1121, P1135, P2167, P2168

P0840 … P0849
r0052 bit 02
Warnings: -
Faults: -
Function chart number: -

Description
The inverter and the user must respond to an extremely wide range of situations and stop
the inverter. In this case, both requirements relating to operations as well as the inverter
protective functions (for example, electrical and thermal overload) and man-machine
protective functions have to be taken into account. As a result of the different OFF/braking
functions (OFF1, OFF2, OFF3) the SINAMICS G120 can flexibly respond to the
requirements mentioned above.

OFF1
The OFF1 command is closely coupled to the ON command. When the ON command is
withdrawn, then OFF1 is directly activated. The motor is braked by OFF1 with the ramp-
down time P1121. If the output frequency falls below the parameter value P2167 and if the
time in P2168 has expired, then the inverter pulses are cancelled.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-63
Functions
8.13 Setpoint channel

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Figure 8-45 OFF1 brake function

Note
OFF1 can be entered using a wide range of command sources via BICO parameter P0840
(BI: ON/OFF1) and P0842 (BI: ON/OFF1 with reversing).
BICO parameter P0840 is pre-assigned by defining the command source using P0700.
The ON and the following OFF1 command must have the same source.
If the ON/OFF1 command is set for more than one digital input, then only the digital input
that was last set, is valid, e.g. DI3 is active.
OFF1 is low active.
When simultaneously selecting the various OFF commands, the following priority applies:
• OFF2 (highest priority)
• OFF3
• OFF1.
OFF1 can be combined with DC current braking or compound braking.
When the motor holding brake MHB (P1215) is activated, for an OFF1, P2167 and P2168
are not taken into account.

OFF2
The inverter pulses are immediately cancelled by the OFF2 command. This means that the
motor coasts down and it is not possible to brake in a controlled fashion.

Control Units CU240S

8-64 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.13 Setpoint channel

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Figure 8-46 OFF2 brake function

Note
The OFF2 command can have one or several sources. The command sources are defined
using BICO parameters P0844 (BI: 1. OFF2) and P0845 (BI: 2. OFF2).
As a result of the pre-assignment (default setting), the OFF2 command is set to the OP. This
source is still available even if another command source is defined (e.g. terminal as
command source → P0700 = 2 and OFF2 is selected using DI2 → P0702 = 3).
OFF2 is low-active.
When simultaneously selecting the various OFF commands, the following priority applies:
• OFF2 (highest priority)
• OFF3
• OFF1.

OFF3
The braking characteristics of OFF3 are identical with those of OFF1 with the exception of
the autonomous OFF3 ramp-down time P1135. If the output frequency falls below parameter
value P2167 and if the time in P2168 has expired, then the inverter pulses are cancelled as
for the OFF1 command.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-65
Functions
8.13 Setpoint channel

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Figure 8-47 OFF3 brake function

Note
OFF3 can be entered using a wide range of command sources via BICO parameters P0848
(BI: 1. OFF3) and P0849 (BI: 2. OFF3).
OFF3 is low active.
When simultaneously selecting the various OFF commands, the following priority applies:
• OFF2 (highest priority)
• OFF3
• OFF1.

8.13.4 Manual and automatic operation

Data

Parameter range: P0700, P1000

P0810, P0811
Warnings: -
Faults: -
Function chart number: -

Description
It is necessary to change-over from the automatic mode into the manual mode to load and
unload production machines and to feed new materials (e.g. batch processing). The machine
operator carries-out the preparatory activities for subsequent automatic operation in the
manual mode. In the manual mode, the machine operator locally controls the machine

Control Units CU240S

8-66 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.13 Setpoint channel

(enters the ON/OFF command as well as also the setpoint). A changeover is only made into
the automatic mode after the set-up has been completed. In the automatic mode, the control
(open-loop) of the machines and production processes are handled by a higher-level control
system (e.g. PLC). This operation is maintained until it is necessary to again load and unload
the machine or feed new material into the machine or production process.
In the SINAMICS G120, indexed parameters P0700 or P1000 and BICO parameters P0810
and P0811 are used to changeover (toggle between) the manual/automatic modes. The
command source is defined using P0700 and the setpoint source is defined using P1000,
whereby index 0 (P0700[0] and P1000[0]) defines the automatic mode and index 1 (P0700[1]
and P1000[1]) the manual mode. BICO parameters P0810 and P0811 are used to
changeover (toggle between) the automatic and manual modes. These BICO parameters
can be controlled from any control source. In so doing, in addition to P0700 and P1000, also
all of the other CDS parameters are changed over (manual/automatic changeover is
generalized as a CDS changeover).

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Figure 8-48 Changing-over using the BICO parameters P0810 and P0811

Table 8-26 Examples of settings of parameter P0810

Parameter setting Command source

P0810 = 722.2 requires P0703 = 99 Digital input 3
P0810 = 2032.15 USS on RS232
P0810 = 2036.15 USS on RS485
P0810 = 2090.15 Fieldbus

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-67
Functions
8.13 Setpoint channel

Table 8-27 Possible settings for parameters P0700 and P1000

Value Command source (P0700) Value Setpoint source (P1000)

1 OP (keyboard) 1 MOP setpoint
2 Terminal strip 2 Analog setpoint
4 USS on RS232 3 Fixed frequency
5 USS on RS485 4 USS on RS232
6 Fieldbus 5 USS on RS485
6 Fieldbus
7 Analog setpoint 2
10 No main setpoint + MOP setpoint
…
77 Analog setpoint 2 + analog setpoint 2

Control Units CU240S

8-68 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.14 Free function blocks

8.14 Free function blocks

Data

Parameter range: P2800 … P2890

Warnings: -
Faults: -
Function chart number: FP4800 … FP4830
Cycle time: 128 ms

Description
For many applications, interlocking logic is required in order to control (open-loop) the
inverter. This interlocking logic couples several states (e.g. access control, plant/system
state) to form a control signal (e.g. ON command). Previously this was implemented using
either a PLC or relays. This represented additional costs for the plant or system. In addition
to logic operations, increasingly, arithmetic operations and storage elements are required in
inverters which generate a new unit from several physical quantities. This simplified PLC
functionality is integrated in the SINAMICS G120 using the freely programmable function
blocks (FFB).
The table below shows the function blocks that are integrated in the SINAMICS G120
inverter:

Table 8-28 Free function blocks

No. Type Example

3 AND AND 1
P2800 P2801[0]

A B C
P2810
A 0 0 0
C
Index0
Index1
B & r2811 0
1
1
0
0
0
1 1 1
3 OR OR 1
P2800 P2801[3]

A B C
P2816
0 0 0
A C
Index0
Index1
B 1 r2817 0
1
1
0
1
1
1 1 1

3 XOR XOR 1
P2800 P2801[6]

A B C
P2822
0 0 0
Index0 A C
Index1
B =1 r2823 0
1
1
0
1
1
1 1 0
3 NOT NOT 1
P2800 P2801[9]

P2828
A C A C
Index0
1 r2829
0 1
1 0

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-69
Functions
8.14 Free function blocks

No. Type Example

2 D-FlipFlops D-FlipFlop 1
P2800 P2801[12]

P2834
SET (Q=1)
Index0
Index1 D Q r2835
Index2
Index3

STORE

Q r2836

RESET (Q=0)

POWER ON
1
SET RESET D STORE Q Q
1 0 x x 1 0
0 1 x x 0 1
1 1 x x Qn-1 Q n-1
0 0 1 1 0
0 0 0 0 1
POWER-ON 0 1

3 RS-FlipFlops RS-FlipFlop 1
P2800 P2801[14]

P2840
SET
Index 0 (Q=1) Q r2841
Index 1

POWER ON 1 RESET
(Q=0) Q r2842

SET RESET Q Q
0 0 Q n-1 Qn-1
0 1 0 1
1 0 1 0
1 1 Q n-1 Qn-1
POWER-ON 0 1

4 Timer Timer 1
P2850 (0.000) P2851(0)
P2800 P2802.0 Delay Time Mode

ON Delay
T 0/10
0

OFF Delay
1/11
0 T
P2849 In
Index0
Out r2852
ON/OFF Delay
2/12
T T NOut
Pulse Generator
1 r2853
T 3/13

2 ADD ADD 1
P2800 P2802[4]

P2869
x1 200%
Index 0 Result r2870
Index 1 x2
-200 %
x1 + x2
Result = x1 + x2
If: x1 + x2 > 200% → Result = 200%
x1 + x2 < -200%→ Result = -200%

Control Units CU240S

8-70 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.14 Free function blocks

No. Type Example

2 SUB SUB 1
P2800 P2802[6]

P2873
x1 200%
Index 0 Result r2874
Index 1 x2
-200 %
x1 + x2
Result = x1 - x2
If: x1 - x2 > 200% → Result = 200%
x1 - x2 < -200% → Result = -200%
2 MUL MUL 1
P2800 P2802[8]

P2877
x1 200%
Index 0 Result
x2 r2878
Index 1
-200 %
x1 ∗ x 2
x1∗ x2
100% Result =
100%
x1∗ x 2
If: > 200% → Result = 200%
100%
x1∗ x 2
< -200%→ Result = -200%
100%

2 DIV DIV 1
P2800 P2802[10]

P2881
x1 200%
Index 0 Result
x2 r2882
Index 1
-200 %
x1 ∗ 100%
X2 x1∗ 100%
Result =
x2
x1∗ 100%
If: > 200% → Result = 200%
x2
x1∗ 100%
< -200% → Result = -200%
x2

2 CMP CMP 1
P2800 P2802[12]

P2885
Index 0 x1
Out
CMP r2886
Index 1 x2

Out = x1 ≥ x2
x1 ≥ x2 → Out = 1
x1 < x2 → Out = 0
Connector Setting in %
2 FFB setpoints P2889
(connector P2890
settings) Range : -200% ... 200%

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-71
Functions
8.14 Free function blocks

The free function blocks (FFB) are enabled in two steps:

1. General enable P2800:
The function "Free function blocks (FFB)" is enabled using parameter P2800 (P2800 =1).
2. Specific enable P2801, P2802:
Using parameter P2801 or P2802, the particular function block is enabled (P2801[x] > 0
or P2802[x] > 0) and the sequence in which they are executed is also defined.
All free function blocks are called within the 128 ms time slice (cycle time). Additionally, to
adapt to the application, the chronological sequence in which the FFBs are executed, can
also be controlled. This is especially important so that the FFBs are executed in the
sequence which is technologically correct. Parameter P2801 and P2802 are used for the
individual enable function as well as to define the priority in which the blocks are executed.
The following priority levels can be assigned:
● 0 = Inactive
● 1 = Level 1
● 2 = Level 2
● 3 = Level 3
The figure below indicates that the priority decreases from the top towards the bottom
(priority 1 → level) or from the right to left (priority 2 → line).

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Figure 8-49 Free function block priorities

Example 1

Enabling the FFBs: P2800 = 1

Enabling individual FFB including assigning a priority:
P2801[0] = 1 AND 1
P2801[1] = 2 AND 2
P2801[2] = 3 AND 3
P2802[12] = 2 CMP 1
P2802[13] = 3 CMP 2
The FFBs are calculated in the following sequence: AND 3 → CMP 2 → AND 2 → CMP 1 → AND 1

Control Units CU240S

8-72 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.14 Free function blocks

Example 2

Enabling the FFBs: P2800 = 1

Enabling individual FFB including assigning a priority:
P2801[3] = 2 OR 1
P2801[4] = 2 OR 2
P2802[3] = 3 Timer 4
P2801[0] = 1 AND 1
The FFBs are calculated in the following sequence: Timer 4 → OR 1 → OR 2 → AND 1
The function blocks are interconnected using BICO technology. In so doing, the function
blocks can be connected with one another as well as to other signals and quantities as long
as these signals or quantities have the appropriate attribute (BO, BI, CO and CI).

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-73
Functions
8.15 Brake functions

8.15 Brake functions

8.15.1 Electro-mechanical brakes

Functions of the electro-mechanical brake

Warning
Dimensioning the electro-mechanical motor brake
The electro-mechanical brake must be dimensioned that, in case of a fault, the complete
motor can be braked to zero from any possible operational speed. If no electro-mechanical
brake is present, the machine manufacturer must adopt other suitable measures to protect
against motion after the energy supply to the motor has been cut (for example, to protect
against sagging loads).

The electro-mechanical brake can be used as motor holding brake or as an instant brake.
● As motor holding brake it is used to prevent the motor from unintented rotation (e.g. lifting
or lowering the load in lifting applications) by applying torque in order to compensate
brake release times. The motor holding brake functionality is triggered by an OFF1 or
OFF3 command. For details see section motor holding brake.
● As an instant brake it slows down the motor from any speed down to zero speed as fast
as possible. The related brake release times are not considered in the case. The instant
brake function is triggered by an OFF2 command. The OFF2 command can be given
manually or triggered automatically by an internal fault condition on the inverter. On Fail-
safe inverters this braking function can also be triggered by the Safe Torque Off (STO)
command or the LSTO fault condition. (reference to the Chapter "Functions", Section
"Safe Brake Control
To keep the electro-mechanical brake open, it must be energised. When power is lost, or
removed from the brake, the brake closes and the motor shaft is held in position.

Note
If an electro-mechanical brake is attached, parameter P1215 needs to be enabled, otherwise
it will not be possible to run the motor!

Control Units CU240S

8-74 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.15 Brake functions

8.15.1.1 Brake Control Relays

Overview
There are two types of brake control relays:
● Brake Module (Relay Brake Module)
● Safe Brake Module (Safe Brake Module)
The Safe Brake Module and the Brake Module are different variants of the same device (for
details see option description "Brake Module Instructions".
Connections of Brake Module and Safe Brake Relay:

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Figure 8-50 Brake Relay

to
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Module (A/B) &75/ M
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Figure 8-51 Wiring of Brake Relay

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-75
Functions
8.15 Brake functions

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Figure 8-52 Safe Brake Module

to
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Figure 8-53 Wiring of Safe Brake Module

With the Safe Brake Module 24 V motor brakes up to a current consumption of 2 A can be
operated. Necessary is an external controlled power supply for 2.5 A and an output voltage
which can be adjusted at a voltage of 26 V, e.g. SITOP modular. The higher voltage is
required to compensate the voltage drop across the cables to the coil of the brake.

Note
On fail-safe reasons it is not allowed to take the 24 V supply of the Control Unit.
The power supply for the Safe Brake Module must be a separate additional power supply.
During power ON for the drive it is necessary to supply the Safe Brake Module first, so that
the Control Unit is able to check its function, otherwise the fault F1601 will occur.

The Safe Brake Module is designed to reaction to a stepped voltage input, which allows the
braking mechanism to be tested. The Brake Module does not have this functionality.

Control Units CU240S

8-76 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.15 Brake functions

Note
During forced dynamisation all connections of the Safe Brake Module are checked but in
operation the connection between Safe Brake Module and brake coil is not monitored.

Triggering the Brake Control with Standard Control Units

The motor brake function can be activated or deactivated via P1215. It controls a brake
relay, connected to the power module. This Brake Module controls an electro-mechanical
brake, which is always closed when powered down.
P1215 = 0
(motor brake not active - factory setting), that means, if a brake is available, it will be closed
to prevent the motor against unintended moves, e.g. after a parameter download.
P1215 = 1
(motor brake active) the brake will be controlled via terminals A and B on the power module.

Triggering the Brake Control with Contol Units with fail-safe functions
Prerequisite: P1215 = 1

Warning
The brake can be triggered via both, a Brake Module and a Safe Brake Relay.
Triggering via a Brake Module is not fail-safe!

For a fail-safe triggering of a Safe Brake Module the following parameters must be set:
P9602 = P9802 = 1 (factory setting is 0). If P9602 ≠ P9802 a fault will be generated.
In case of P9602 = P9802 = 1 a test signal regarding the signal to the Safe Brake Control is
generated and monitored.
This test signal does not interfere with the normal function of the mechanical brake. If the
mechanical brake is fitted and the test fails, a fault condition will be indicated by the inverter.
If the Safe Brake Control is deactivated by setting P9602 = P9802 = 0 the Safe Brake
Module will still work as intendet but will not be monitored in a safe way.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-77
Functions
8.15 Brake functions

8.15.1.2 Motor Holding Brake

Data

Parameter range: P1215

P0346, P1216, P1217, P1080
r0052 bit 12
Warnings: -
Faults: -
Function chart number: -

Description
For motors which must be secured when powered-down to prevent undesirable movement,
the SINAMICS G120 brake sequence control (enabled through P1215) can be used to
control the motor holding brake.
Before opening the brake, the pulse inhibit must be removed and a current impressed which
keeps the motor in that particular position. In this case, the impressed current is defined by
the min. frequency P1080. A typical value in this case is the rated motor slip r0330. In order
to protect the motor holding brake from continuous damage, the motor may only continue to
move after the brake has been released (brake release times are between 35 ms and
500 ms). This delay must be taken into account in parameter P1216 "Holding brake release
delay" (see figure below).

Control Units CU240S

8-78 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.15 Brake functions

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Figure 8-54 Motor holding brake after ON/OFF1 resp. ON/OFF3

The motor holding brake is either closed using OFF1 or OFF3. When the minimum
frequency P1080 is reached, the motor is operated at this frequency until the brake has been
applied (closing times of brakes are between 15 ms and 300 ms). The actual time is
specified using parameter P1217 "Holding time after ramp down" (see figure above). If, on
the other hand, an OFF2 command has been output, then independent of the motor state,
the status signal r0052 bit 12 "Brake active" is reset. This means that the brake immediately
closes after OFF2 (instant brake).
The mechanical brake is controlled using the status signal r0052 bit 12 "Brake active" of the
brake control. This signal is connected to terminal A and B of the power module.

Warning
It is not sufficient to select the status signal r0052 bit 12 "Brake active" in P0731 … P0733. In
order to activate the motor holding brake, in addition, parameter P1215 must also be set to
1.
If SINAMICS G120 controls the motor holding brake, then a series commissioning may not
be carried-out for potentially hazardous loads (e.g. suspended loads for crane applications)
unless the load has been secured. Potentially hazardous loads can be secured as follows
before series commissioning is started:
• Lower the load to the floor, or
• Clamp the load using the motor holding brake
(Caution: During the series commissioning, SINAMICS G120 must be prevented from
controlling the motor holding brake).

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-79
Functions
8.15 Brake functions

Note
Motors have optional holding brakes which are not designed to be used as brakes for normal
operation. The holding brakes are only designed for a limited number of emergency braking
operations / motor revolutions with the brake closed (refer to the Catalog data).
When commissioning a motor with integrated holding brake it is therefore absolutely
imperative that it is ensured that the holding brake functions perfectly. A "clicking noise" in
the motor indicates that the brake has been correctly released.

Before the motor holding brake is applied, a torque must be established that maintains the
motor at the required position. The pulses, from the inverter, must be enabled to allow the
necessary torque to be generated. The torque is defined by the minimum frequency in
parameter P1080. A typical value for this is the rated motor slip r0330. Additionally, this
torque can be modified using the following parameters:
● V/f control – boost parameter P1310
● SLVC – boost parameters P1610 and P1611
● VC – supplementary torque setpoint P1511
The motor holding brake can be permanently damaged, if the motor shaft is moved when the
motor holding brake is applied. It is imperative that the release of the motor holding brake is
timed correctly.

8.15.1.3 Instant brake

Data

Parameter range: P1215

P0346, P1216, P1217, P1080
r0052 bit 12
Warnings: -
Faults: -
Function chart number: -

Description
An instant brake is an electro-mechanical brake which has to brake down the motor from any
speed down to zero speed. The instant brake function is activated after an OFF2 command
and additional in the case of a fail-safe application after a Safe Torque Off (STO) or a LSTO
fault condition (refer to Chapter "Functions", Section "Safe Brake Control").
The behavior of the instant brake function is described below.

Control Units CU240S

8-80 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.15 Brake functions

212))
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Figure 8-55 Instant Brake

Warning
Dimensioning the electro-mechanical motor brake
The electro-mechanical brake must be dimensioned that, in case of a fault, the complete
motor can be braked to zero from any possible operational speed.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-81
Functions
8.15 Brake functions

8.15.2 Electronic brakes (only with PM240)

Overview
The SINAMICS G120 inverter has three electronic braking technologies:
● DC braking
● Compound braking
● Dynamic braking
These brakes can actively brake the motor and avoid a possible DC link overvoltage
condition. The figure below shows the inter-dependency of the electronic braking functions.

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Figure 8-56 Inter-dependency of electronic brakes

8.15.2.1 DC braking

Data

Parameter range: P1230, P1233

P1232, P1234
r0053 Bit00
Warnings: -
Faults: -
Function chart number: -

Description
The motor decelerates along a parameterized braking ramp if an OFF1 or OFF3 command is
output. A "flat" ramp must be selected so that the inverter is not tripped (shutdown) due to
the high regenerative energy which would cause a DC link overvoltage condition. The DC
brake should be activated while the OFF1 or OFF3 command is present if the motor is to be
braked faster. For DC braking, instead of continually reducing the output frequency/voltage
during the OFF1 or OFF3 phase, from a selectable frequency, a DC voltage/current is input
(refer to sequence 1).
The motor can be brought to a standstill in the shortest time using DC current braking (DC
brake). DC braking is selected as follows:

Control Units CU240S

8-82 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.15 Brake functions

● After OFF1 or OFF3 (the DC brake is released via P1233) ‒ Sequence 1

● Directly selected using BICO parameter P1230 ‒ Sequence 2
For DC braking, a DC current is impressed in the stator winding which results in a significant
braking torque for an induction motor. The magnitude, duration and frequency at which
braking starts can be set for the braking current and therefore braking torque by setting the
appropriate parameters. The DC brake can therefore support a braking operation from
approx. < 10 Hz or prevents / minimizes the increase in the DC link voltage for regenerative
braking. This is realized because energy is directly absorbed in the motor. The essential
advantage and the main application of the DC brake is the fact that a holding torque can be
generated at standstill (0 Hz). For instance, this is important forapplications where after
positioning, any motion in the mechanical system / product itself can result in waste.
DC braking is especially used for:
● Centrifuges
● Saws
● Grinding machines
● Conveyor belts

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-83
Functions
8.15 Brake functions

Sequence 1
1. Enabled using P1233
2. DC braking is activated with the OFF1 or OFF3 command (see figure below)
3. The inverter frequency is ramped down along the parameterized OFF1 or OFF3 ramp
down to the frequency at which DC braking is to start - P1234. This means that the kinetic
energy of the motor can be reduced without endangering the inverter. However, if the
ramp-down time is too short, there is a danger that a fault will be output as a result of an
overvoltage condition in DC link - F0002.
4. The inverter pulses are inhibited for the duration of the de-magnetizing time P0347.
5. The required braking current P1232 is then impressed for the selected braking time
P1233. The status is displayed using signal r0053 bit 00.
The inverter pulses are inhibited after the braking time has expired.


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Figure 8-57 DC braking after OFF1/OFF3

Control Units CU240S

8-84 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.15 Brake functions

Sequence 2
1. Enabled and selected using BICO parameter P1230 (see figure below).
2. The inverter pulses are inhibited for the duration of the de-magnetizing time P0347.
3. The requested braking current P1232 is impressed as long as DC braking is enabled
(P1230 = 1) and the motor is braked. This state is displayed using signal r0053 bit 00.
4. After DC braking has been cancelled, the motor accelerates back to the setpoint
frequency until the motor speed matches the inverter output frequency. If there is no
match, then there is danger that a fault will be output as a result of overcurrent - F0001.
This can be avoided by activating the flying restart function.
5. If any fault occurs during P1230 = 1 the DC current is set to zero. The motor doesn't ramp
up even the fault is acknowledged. A new ON command is necessary.
6. If the DC brake is enabled again, the braking current P1232 is impressed as long as
P1230 = 1.

2

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Figure 8-58 DC braking after external selection

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-85
Functions
8.15 Brake functions

Note
1. The "DC braking" function is only practical for induction motors!
2. DC braking is not suitable to hold suspended loads!
3. For DC current braking, the motor kinetic energy is converted into thermal energy in
the motor. If braking lasts too long, then the motor can overheat!
4. While DC braking, there is no other way of influencing the motor speed using an
external control. When parameterizing and setting the motor system, then as far as
possible, it should be tested using real loads!

8.15.2.2 Compound braking

Data

Parameter range: P1236

Warnings: -
Faults: -
Function chart number: -

Description
For compound braking (this is enabled using P1236) DC braking is superimposed with
regenerative braking (where the motor regenerates into the line supply as it brakes along a
ramp). If the DC link voltage exceeds the compound switch-in threshold VDC-Comp (see
figure below), then a DC current is impressed as a function of P1236. In this case, braking is
possible with a controlled (closed-loop) motor frequency and minimum regenerative
feedback. Effective braking is obtained without having to use additional components by
optimizing the ramp-down time (P1121 for OFF1 or when braking from f1 to f2, P1135 for
OFF3) and using compound braking P1236.

Control Units CU240S

8-86 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.15 Brake functions

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Figure 8-59 Compound braking

The compound braking switch-in threshold VDC-Comp is calculated as a function of

parameter P1254 (Auto detect VDC switch-on levels) either directly using the line supply
voltage P0210 or indirectly using the DC link voltage and r1242 (refer to the formula in the
figure above).

Warning
For compound braking, regenerative braking is superimposed on the DC braking (braking
along a ramp). This means that components of the kinetic energy of the motor and motor
load are converted into thermal energy in the motor. If this power loss is too high or if the
braking operation takes too long, then this can cause the motor to overheat!

Note
Only active in conjunction with V/f control.
Compound braking is deactivated, if:
• flying restart is active,
• DC braking is active, and
• Vector control is selected.
The compound switch-in threshold VDC-Comp is dependent on P1254:
VDC-Comp(P1254 = 0) ≠ VDC-Comp(P1254 ≠ 0)

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-87
Functions
8.15 Brake functions

8.15.2.3 Dynamic braking

Data

Parameter range: P1237

Warnings: A0535
Faults: F0022
Function chart number: -

Description
For several motor applications, in certain operating states, the motor can regenerate.
Examples of these applications include:
● Cranes
● Traction motors
● Conveyor belts which transport loads downwards.
When the motor is in the regenerative mode, the energy from the motor is fed back into the
DC link of the motor through the inverter. This means that the DC link voltage increases and
when the maximum threshold is reached, the inverter is shutdown (tripped) with fault F0002.
This shutdown (trip) can be avoided by using dynamic braking. Contrary to DC and
compound braking, this technique requires that an external braking resistor is installed.
The advantages of dynamic resistor braking include:
● The regenerative energy is not converted into heat in the motor.
● It is significantly more dynamic and can be used in all operating states (not only when an
OFF command is output).

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Figure 8-60 Connecting the chopper (braking) resistor

The braking energy in the DC link is converted into heat when dynamic braking is activated
(enabled using P1237). The energy is converted into heat using the voltage-controlled
chopper resistor (ballast resistor). When regenerative energy is fed back to the DC link and
in consequence the DC link threshold VDC, Chopper is exceeded, then the chopper resistor is
switched in using an electronic semiconductor switch.
Switch-in threshold of the chopper resistor:
If P1254 = 0: VDC, Chopper = 1.13 ⋅ 2 ⋅ Vline supply = 1.13 ⋅ 2 ⋅ P0210
Otherwise: VDC, Chopper = 0.98 ⋅ r1242

Control Units CU240S

8-88 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.15 Brake functions

The chopper switch-in threshold VDC chopper is calculated as a function of parameter P1254
(Auto detect VDC switch-on levels), either directly using the line supply voltage P0210 or
indirectly using the DC link voltage and r1242.

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Figure 8-61 Mode of operation of the dynamic braking

The regenerative (braking) energy is converted into thermal energy using the chopper
resistor. A braking module (chopper control) is integrated in the DC link for this purpose. The
chopper of the braking module switches the resistor with a mark-space ratio corresponding
to the regenerative power to be dissipated. The braking module is only active if, as a result of
the regenerative operation, the DC link voltage lies above the chopper switch-in threshold
VDC chopper. This means that the braking module is not active in normal operation when
motoring.
The chopper resistor is only designed for a specific power and a certain load duty cycle and
can only absorb a limited amount of braking energy within a specific time period. The
chopper resistors, specified in SINAMICS G120 Catalog, have the following load duty cycle
as shown in the figure below.

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Figure 8-62 Load duty cycle - chopper resistors

This load duty cycle is saved in the SINAMICS G120 inverter for P1237 = 1 (→ 5 %). If the
values are exceeded due to the load required, then when the maximum acceptable braking
energy is reached, the load duty cycle monitoring controls the chopper so that the value is
reduced to the value entered in parameter P1237. This means that the energy to be

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-89
Functions
8.15 Brake functions

dissipated in the chopper resistor is reduced, which means that the DC link voltage quickly
increases due to the regenerative energy available and the inverter is shutdown (tripped)
due to a DC link overvoltage condition.
If the continuous power or the load duty cycle for a resistor is too high, then the continuous
rating can be quadrupled using four resistors in a bridge circuit configuration (see figure
below). In this case, in addition, the load duty cycle must be increased using parameter
P1237 from P1237 = 1 (→ 5 %) to P1237 = 3 (→ 20 %). When using the bridge circuit, the
overtemperature switch of the resistors should be connected in series and incorporated in
the fault circuit. This guarantees, that when a resistor overheats, the complete
system/inverter is shut down.

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Figure 8-63 Increasing the level of braking energy which can be absorbed

The continuous power and the load duty cycle are modified using parameter P1237. If the
load duty cycle monitoring switches from the peak power (100 %) to the continuous power,
then this is dissipated for an unlimited length of time in the braking resistor. Contrary to the
braking resistor, as listed in the Catalog, the chopper control can be permanently operated
with 100 % power.

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Figure 8-64 Chopper load duty cycle

For SINAMICS G120, the braking module is integrated in the inverter and the braking
resistor can be connected using the external terminals DCP/R1 and R2 (for more details
refer to Operating Instructions of the corresponding Power Module). Where the DCP/R1 is
the positive terminal for the braking resistor and R2 is the negative terminal for the braking
resistor.

Control Units CU240S

8-90 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.15 Brake functions

Warning
Braking resistors, which are to be mounted on SINAMICS G120, must be designed so that
they can tolerate the power dissipated.
If an unsuitable braking resistor is used there is a danger of fire and that the associated
inverter will be significantly damaged.
The chopper control, integrated in the inverter is designed for the braking resistor value
assigned in Catalog; e.g.:
• Power Module PM240 6SL3224-0BE24-0AA0
• brake resistor 6SL3201-0BE12-0AA0
• brake resistor value 160 Ω
A brake resistor with a lower resistance value will destroy the inverter. In this case, an
external braking unit must be used.
When operational, the temperature of braking resistors increases – do not touch! Ensure that
there is sufficient clearance around the unit and there is adequate ventilation.
A temperature protection switch must be used to protect the units against overheating.

Note
The switch-on threshold VDC chopper of the dynamic resistor braking is dependent on P1254
VDC chopper(P1254 = 0) ≠ VDC chopper(P1254 ≠ 0).
External braking modules (chopper units) including braking resistor can be used with all of
the sizes of inverters. When engineering the system, the particular braking module/resistor
must be taken into consideration.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-91
Functions
8.15 Brake functions

8.15.3 Regenerative braking (only with PM250)

Data

Parameter range: P0307, P0310

P1082, P1531
r1537
Warnings: A0502
Faults: F0002, F0028
Function chart number: -

Description
For certain drive applications, the motor can operate as a generator in specific operating
states. Typical examples of these types of applications include:
● Cranes
● Traversing drives
● Conveyor belts where the material is being transported downwards
For regenerative motor operation, the motor energy is fed back into the mains supply via the
inverter and the mains-commutated rectifier of the inverter. The advantages of regenerative
braking include:
● The kinetic energy is not converted into heat in the motor
● The kinetic energy does not have to be converted into heat in an external resistor
● It has a significantly higher dynamic response and can be used in all operating states (not
only for an OFF command)
● It allows precise braking along a down ramp
● Continuous regenerative operation is possible - e.g. for cranes
● Only a low level of harmonics are injected back into the mains supply for regenerative
braking

Note
If regenerative feedback into the line supply is required at the rated frequency the
maximum frequency (p1082) must be greater than the rated motor frequency (p0310).

Caution
If the power fed back into the mains supply exceeds the rated power of the inverter, the
inverter will trip with F0028.

Control Units CU240S

8-92 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.16 Automatic restart

8.16 Automatic restart

Data

Parameter range: P1210

P1211
Warnings: A0571
Faults: F0035
Function chart number: -

Description
After a power failure (F0003 "Undervoltage"), the "Automatic restart" function, enabled using
P1210, will on next power up automatically acknowledge any faults and start the inverter
again.
The automatic restart function will only take place if a RUN command was present prior to
the power failure. For automatic restart to be performed a RUN command must be present
on power up and must also have been present prior to power failure.
When it comes to power failures (line supply failure), then a differentiation is made between
the following conditions:

Line undervoltage (brownout)

"Line undervoltage" is a situation where the line supply is interrupted and returns before (if
installed) the OP display has gone dark (this is an extremely short line supply interruption
where the DC link hasn't completely collapsed).

Line failure (blackout)

"Line failure" is a situation where the display on the OP has gone dark (this represents a
longer line supply interruption where the DC link has completely collapsed) before the line
supply returns.
The automatic restart function P1210 is shown in the table below as a function of external
states/events.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-93
Functions
8.16 Automatic restart

Table 8-29 Automatic restart

P1210 ON always active Inverter ON and no

RUN command
Fault F0003 for All other faults for All faults + F0003
Blackout Brownout Blackout Brownout
0 --- --- --- --- ---
1 Fault acknowledge --- --- --- Fault acknowledge
2 Fault acknowledge See Caution * --- --- ---
+ restart
3 Fault acknowledge Fault acknowledge Fault acknowledge Fault acknowledge ---
+ restart + restart + restart + restart
4 Fault acknowledge Fault acknowledge --- --- ---
+ restart + restart
5 Fault acknowledge See Caution * --- Fault acknowledge Fault acknowledge
+ restart + restart
6 Fault acknowledge Fault acknowledge Fault acknowledge Fault acknowledge Fault acknowledge
+ restart + restart + restart + restart

Caution
*) Automatic restart with external 24 V supply
If the Control Unit is powered by an external 24 V supply and the mains line supply fails, the
Power Module will lose power, but the Control Unit will remain active. If this situation occurs
then the Control Unit will not perform an automatic restart. This situation could result in the
inverter being in an undetermined state and may not react as predicted.
Source command for automatic restart
The automatic restart function has been designed to ignore command source time-outs. That
is, if the command sources is, for example, a PLC or through USS communications and the
PLC or USS times-out an automatic restart will not be initiated.

The number of start attempts is specified using parameter P1211. The number is internally
decremented after each unsuccessful attempt. After all attempts have been made (as
specified in parameter P1211), automatic restart is cancelled with the message F0035. After
a successful start attempt, the counter is again reset to the initial value.

Control Units CU240S

8-94 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.16 Automatic restart

Danger
For longer line supply failures (blackouts) and when the automatic restart function is
activated, over a longer period of time it may be assumed that SINAMICS G120 is powered-
down. However, when the line supply returns, inverters can automatically start to run again
without any operator intervention.
If the operating range of the motor is entered in this status, this can result in death, severe
injury or material damage.

Note
In addition the "Flying restart" function must be activated if, for an automatic restart, the
inverter is to be connected to a motor which may already be spinning.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-95
Functions
8.17 Flying restart

8.17 Flying restart

Data

Parameter range: P1200

P1202, P1203
r1204, r1205
Warnings: -
Faults: -
Function chart number: -

Description
The "Flying restart" function (this is enabled using P1200) allows the inverter to be switched
to a motor which is still spinning. If the inverter was to be powered-up without using the flying
restart function, there would be a high possibility that a fault with overcurrent F0001 would
occur. The reason for this is that the flux must first be established in the motor and the V/f
control or closed-loop Vector control must be set corresponding to the actual motor speed.
The inverter frequency is synchronized with the motor frequency using the flying restart
function.
When the inverter is normally powered-up it is assumed that the motor is stationary and the
inverter accelerates the motor from a standstill and the speed is ramped-up to the setpoint
which has been entered. However, in many cases this condition is not fulfilled. A fan motor is
a typical example. When the inverter is powered-down the air flowing through the fan can
cause it to rotate in any direction.

Table 8-30 Settings for parameter P1200

P1200 Flying restart active Search direction

0 Disabled -
1 Always Start in the direction of the setpoint
2 For line supply on and fault Start in the direction of the setpoint
3 For fault and OFF2 Start in the direction of the setpoint
4 Always Only in the direction of the setpoint
5 For line supply on, fault and OFF2 Only in the direction of the setpoint
6 For fault and OFF2 Only in the direction of the setpoint

Control Units CU240S

8-96 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.17 Flying restart

Flying restart without speed encoder

Depending on parameter P1200, after the demagnetization time has expired P0347, flying
restart is started with the maximum search frequency fsearch,max (see figure below).
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This is realized either after the line supply returns when the automatic restart function has
been activated or after the last shutdown with the OFF2 command (pulse inhibit).
● V/f characteristic (P1300 < 20):
The search frequency is reduced, as a function of the DC link current with the search rate
which is calculated from parameter P1203. In so doing, the parameterizable search
current P1202 is impressed. If the search frequency is close to the rotor frequency, the
DC link current suddenly changes because the flux in the motor establishes itself. Once
this state has been reached, the search frequency is kept constant and the output voltage
is changed to the voltage value of the V/f characteristic with the magnetization time
P0346 (see figure below).
● Closed-loop Vector control without encoder (SLVC):
Starting from the initial value, the search frequency approaches the motor frequency with
the impressed current P1202. The motor frequency has been found if both frequencies
coincide. The search frequency is then kept constant and the flux setpoint is changed to
the rated flux with the magnetization time constant (dependent on P0346).
After the magnetization time P0346 has expired, the ramp-function generator is set to the
speed actual value and the motor is operated with the actual reference frequency.

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Figure 8-65 Flying restart

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-97
Functions
8.17 Flying restart

Flying restart with speed encoder

Depending on parameter P1200, after the demagnetization time P0347 expires, the flying
restart is started with the maximum search frequency fsearch,max.
1. After the line supply returns with the automatic restart active
2. After the last shutdown using the OFF2 command (pulse inhibit)
● V/f characteristic (P1300 < 20):
For V/f control, the output voltage of the inverter is linearly increased from 0 to the V/f
characteristic value within the magnetization time P0346.
● Closed-loop Vector control with speed encoder (VC):
For the closed-loop Vector control, the necessary magnetization current is established
within the magnetization time P0346.
After the magnetization time P0346 has expired, the ramp-function generator is set to the
speed actual value and the motor is operated at the actual setpoint frequency.

Warning
When "Flying restart" is activated (P1200 > 0), although the motor is at a standstill and the
setpoint is 0, it is possible that the motor can be accelerated as a result of the search
current!
If the operating range of the motor is entered when the motor is in this state, this can result in
death, severe injury or material damage.

Note
If a higher value is entered for the search velocity P1203 this results in a flatter search curve
and therefore to an extended search time. A lower value has the opposite effect.
For "Flying restart", a braking torque is generated which can cause motors, with low
moments of inertia, to brake.
For group motors, "Flying restart" should not be activated due to the different characteristics
of the individual motors when coasting down.

Control Units CU240S

8-98 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.18 Fail-safe functions

8.18 Fail-safe functions

Overview

Warning
Installation and protection level of Control Units in fail-safe systems
All installation areas for Control Units with fail-safe functions as well as outside installed
components of the according fail-safe system, if correctly installed, must comply with the
minimum protection level of IP54 [see EN 60529 (IEC 60529)].
Change of Control Units with fail-safe functions
When carrying out a swap of Control Units, it is not allowed to replace a Control Unit with
fail-safe functions with a Standard Control Unit. Replacing a Control Unit with fail-safe
functions with a Standard Control Unit disables all fail-safe functions that have been
implemented and therefore can lead to personal injury and damage to the machine. A
replacement of fail-safe components with standard components has to be considered as a
completely new application and re-commissioned as such.
Dimensioning of the Motor
If regenerative loads occur in the application, the motor must be dimensioned so that its slip
in super-synchronous operation always remains below the rated slip.
Dimensioning of the Motor holding brake
The motor holding brake must be dimensioned that in case of a fault the complete drive can
be braked to zero from any possible operational speed. If no holding brake is present, the
machine manufacturer must adopt other suitable measures of protection against motion after
the power to the motor has been cut (e.g. to protect against sagging loads).
Regenerative load with SLS
With the fail-safe functions "safely limited speed" (SLS) and "safe stop 1" (SS1) operation
with permanent regenerative loads is not permitted.

Note
In order to verify the parameters for the fail-safe functions, an acceptance test must always
be carried-out after commissioning, reset and also when changing a completely backed-up
data set of the parameters for the fail-safe functions. This acceptance test must be
appropriately logged and documented. For more details refer to Section "Acceptance Test
and Acceptance Log" In Chapter "Commissioning".

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-99
Functions
8.18 Fail-safe functions

The Control Unit with fail-safe functions has specific fail-safe functions integrated into its
system. These are:
● Safe Torque Off (STO)
● Safe Stop 1 (SS1)
● Safely-Limited Speed (SLS)
● Safe Brake Control (SBC)
These functions are controlled using either the fail-safe digital inputs on the front of the CU,
PROFIsafe via PROFIBUS-DP interface located at the bottom of the CU. See figure below.

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Figure 8-66 Control Unit with fail-safe functions

Fail-safe functions are only available on the Control Units with fail-safe functions. On the
standard CUs, the fail-safe features are not available.
The parameters for the fail-safe functions are held on two separate processors within the
control unit. Each processor holds a unique copy of the parameterized fail-safe function.
These unique copies of the parameterized fail-safe function are accomplished by double-
parameters. Double-parameters have their own unique number, but have identical
functionality. Each processor controls two separate and isolated shutdown control
mechanisms which are continually monitored by the system to ensure they are operating
correctly. Should a discrepancy occur, then the Latched Safe Torque Off is activated.

Control Units CU240S

8-100 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.18 Fail-safe functions

8.18.1 Monitoring the fail-safe functions

Overview
There are three monitoring procedures:
● Time controlled request for forced dynamisation
● Forced dynamisation
● Process dynamisation
The dynamisation process is designed to detect software and hardware faults of the two
shutdown paths. The forced dynamisation consists of a processor self-test of both
processors within the Control Unit and a hardware test. The hardware test includes a test to
ensure, that if fitted, the Safe Brake Control is functioning correctly.

Note
In fail-safe applications it is necesarry that the forced dynamisation process takes place
during regular intervals. The minimum is once a year.

Time controlled request for forced dynamisation

When the time, set in P9659 (hours or fractions of hours), has expired, a warning A1699 is
issued by the system. This warning can only be cleared by performing a forced
dynamisation. If the forced dynamisation is successful, the timer will be reset to the value in
P9659 and the inverter will be ready to run. If the forced dynamisation fails, the timer will
remain at 0 and the inverter will be disabled from running.
The time remaining until the next forced dynamisation becomes necesarry is displayed in
r9660.
With each forced dynamisation r9660 is reset to the value of P9659.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-101
Functions
8.18 Fail-safe functions

Forced dynamisation
The forced dynamisation process delays the switch-on process after a Safe Torque Off
(STO), but it ensures that all the fail-safe features of the inverter are functioning correctly.
However, should this delay after a STO be unacceptable for the user application, it can be
disabled by setting parameters P9601 = P9801 = 0.
The forced dynamisation process is automatically initiated by the following events:
● On power-up of the inverter.
● When the Latched Safe Torque Off (LSTO) function is deactivated.
● When the Safe Torque Off (STO) is left (if P9601 = P9801 = 2).
● When Safe Stop 1 (SS1) is left after STO was reached (if P9601 = P9801 = 2).
● When commissioning of fail-safe functions is left.

Note
When carrying-out the forced dynamisation, the shutdown paths of the motor brake are
also tested. This results a brief opening command (2 ms to 30 ms) in the motor brake.
The mechanical part of the brake generally requires longer than 30 ms to open. This
means that this dynamic operation generally has no influence on the motor shaft itself.

Process dynamisation
The process dynamisation will be performed after STO initialisation or SS1 end only if P9601
= P9801 = 2.
The testing includes both shutdown paths, but does not perform a processor self-test or a
test of the Safe Brake Control.

Warning
Dynamisation of the shutdown paths
For safety reasons, it is necessary to initiate a safe torque off as a test at intervals of
maximal 8760 hours (one year) in order to check its operability. Thus, 8760 hours after the
last activation of the safe torque off the converter sets a status bit that specifies this
requirement.
The process control must then initiate the safe torque off at the next opportunity, for
example, when the drive has in any case a short phase with zero speed. If the converter
returns the "safe torque off initiated" status signal, the torque off can be released again. The
setting and clearing of the status bit and the dynamisation must be logged as process data
by the higher-level control.

Control Units CU240S

8-102 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.18 Fail-safe functions

8.18.2 Limiting values for SS1 and SLS

Maximum fault reaction time

The maximum fault reaction time during active safe braking ramp (used in SS1 and SLS) is
given as delay from crossing the parameterised envelope until triggering an LSTO.

actual
frequency

LSTO limit
setpoint
frequency

envelope

envelope fault
delay reac-
Δtenvelope tion
time
Δtreact.
time W

Figure 8-67 Maximum shut-dowwn time

Description
When parameterising the limiting envelope for SLS and SS1 with P9680/P9880 and
P9691/P9891 the following minimum tolerances should be considered to provide maximum
performance of the drive:

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-103
Functions
8.18 Fail-safe functions

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Figure 8-68 Safety limits for SLS and SS1

Control Units CU240S

8-104 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.18 Fail-safe functions

1. The minimum monitoring speed tolerance p9691 should be set to

P9691 ≥ 1.15 ∙ P9690 + ∆Fslip
thus defining the minimum frequency tolerance as
∆F = P9691 - P9690 - ∆Fslip
Where ∆Fslip is given as
∆Fslip = P0330∙ r0310 / 100%
This prevents sporadic trips caused by measurement inaccuracies and additional slip
compensation. Note that according to the above formula, P9691 must be set, even if SLS
is not parameterised.
2. The resulting frequency tolerance ∆Fhigh due to the minimum frequency tolerance at high
frequencies is then given as
∆Fhigh ≥ 0.15 ∙ Fmax - ∆F
where Fmax defines the maximum process frequency at initiation of SLS or SS1.
3. The resulting frequency tolerance ∆ Flow due to the minimum frequency tolerance at low
frequencies is then given as
˂)ORZ싩 P ˂)
 '
where the gradient m is defined as

P 
3

The denominator D in the above formula is calculated as follows:
SLS parameterised: D = 2 ∙ P9690
SS1 parameterised: D = 2 ∙ P9682
SLS and SS1 parameterised: D = 2 ∙ min [P9682, P9690]
4. The valid delay ∆Fdelay is then given as maximum of
∆Fdelay = max [∆Flow, ∆Fhigh]
5. Finally the minimum braking ramp delay can be calculated as
˂)GHOD\
3싩
 P

The safe frequency envelope results from a time delay (p9680) in t-direction and an
additional frequency tolerance ∆F (caused by measurement inaccuracies) and ∆Fslip (caused
by slipcompensation) in F-direction.

Fault reaction time

An LSTO is always triggered immediately after the parameterised safe envelope frequency is
exceeded. However, note that the actual frequency may deviate (is usually higher) from the
set point frequency due to normal operating states (slip compensation, PID, etc.) or internal
drive faults.
Therefore, as the envelope starting frequency is related to the actual frequency the
parameterised envelope may be shifted as show in the next figure.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-105
Functions
8.18 Fail-safe functions

I
actual shifted envelope
frequency
maximum application related
reachable frequency Fmax reached

LSTO limit
setpoint
frequency

envelope fault
delay reac-
Δtenvelope tion
time
Δtreact.
time W

Figure 8-69 Maximum fault reaction time

The maximum envelope shift corresponds to the fault reaction time ∆t reactiontime
(maximum LSTOlimit) wich is given as:
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Control Units CU240S

8-106 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.18 Fail-safe functions

8.18.3 Safe Torque Off

Data

Parameter range: P0003, P0010

P09761
P9603/P9803, Bit 04, Bit 05 or Bit 07 (PROFIsafe)
P9690/P9890
P9691/P9891
P9692/P9892
P9799/P9899/P3900
Warnings A1691, A1692, A1696, A1699
Faults F1600, F1616

Description
Safe Torque Off (STO) is the simplest fail-safe function and its purpose is to shutdown the
motor safely. Once the motor is at a standstill, STO then enables a switch-on lock which
prevents the inverter from starting the motor, unless the STO signal is removed. Shutting
down of the triggering pulses on the Power Module effectively stops the motor and should a
mechanical brake be connected, it will be closed immediately.
When the STO function is initiated the inverter performs the following actions:
1. The triggering pulses on the Power Module are disabled.
2. The mechanical brake (if connected) is closed immediately.
3. The status LED STO starts flashing.
4. The status LED ES is switched on, indicating the end-of-state has been reached.
When the STO signal is removed the inverter performs the following actions:
1. The process dynamisation is carried out (always).
2. The forced dynamisation procedure is carried out (if parameterised by p9601 and p9801).
3. The forced dynamisation timer (p9660) is reset to the value in p9659 (if the forced
dynamisation procedure was carried out successfully).
4. The mechanical brake is opened (if connected), if not closed by holding brake function
(P1215).
5. The status LED STO is switched on and ES is switched off.
6. The pulse-lock must be released by applying a rising edge signal (OFF1/ON).
These actions are shown in the figure below.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-107
Functions
8.18 Fail-safe functions

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Figure 8-70 Safe Torque Off function

The STO function has the highest priority and cannot be intercepted by any other function.

Note
The state of the fail-safe functions is announced by r9772.

Caution
Reaction time
The reaction time for a STO is 20 ms.
Fault reaction time
An internal failure during a STO will be detected within 20 ms and leads immediately to a
LSTO.
The overall reaction time is the sum of reaction time and fault reaction time.

Control Units CU240S

8-108 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.18 Fail-safe functions

Latched Safe Torque Off (LSTO)

The latched safe torque off (LSTO) is always initiated when a detected fault requires, that the
drive must be brought to a standstill. The drive can be returned to operation only when the
fault has been explicitly acknowledged and a forced dynamisation procedure has been
carried out.
The latched safe torque off state is left by the following procedure:
1. Turning the drive off by sending an OFF1-signal.
2. Acknowledging all active faults.
3. Sending an ON-signal after the dynamisation procedure was carried out successfully.

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Figure 8-71 Latched safe torque off function

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-109
Functions
8.18 Fail-safe functions

Caution
After an STO or LSTO it is possible (but almost unlikely) that the field generating
components become faulty in a way that they will generate one single rising edge of a
rotating field causing the motor to jerk for a defined maximum electrical angle of 60 °.
The resulting rotating angle at the motor shaft is smaller than the maximum electrical
angle due to inertia and the number of pole pairs.

Note
A latched safe torque off is always initiated by a safety fault condition within the drive.
Therefore, the drive always performs a forced dynamisation procedure before it is
allowed to restart.

8.18.4 Safe Stop 1

Data

Parameter range: P0003, P0010

P09761
P9603/P9803, Bit 02, Bit 03 or Bit 07 (PROFIsafe)
P9680/P9880
P9681/P9881
P9682/P9882
P9799/P9899/P3900
Warnings A1691, A1692, A1696, A1699
Faults F1600, F1616

Description
In contrast to STO, the actual speed of the motor has an influence on the behavior of the
SS1 (Safe Stop 1) function. When SS1 is initiated the speed of the motor is detected, if the
speed of the motor is lower than the minimum speed for standstill detection set in P9682 and
P9882, the STO function is initiated immediately to bring the motor to a standstill. If the
motor speed is higher than the minimum speed for standstill detection, then the motor is
slowed down using the safe braking-ramp time set in P9681 and P9881. See figure below.

Control Units CU240S

8-110 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.18 Fail-safe functions

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Figure 8-72 Safe Stop 1 (SS1) function

When SS1 is activated, the following actions are performed by the inverter:
1. Both shutdown paths initiate a controlled safe brake ramp function, including detecting
the speed of the motor.
2. The motor is slowed down by the safe brake ramp function.
3. The status LED SS1 starts flashing.
4. When the minimum speed for standstill detection is reached, the STO function is
activated.
5. The mechanical brake (if fitted) is closed.
6. The status LED ES is switched on.
The SS1 function can be interrupted by either an OFF2 command or the STO function.
When SS1 is deactivated before the "minimum speed for standstill detection" (P9682/P9882)
is reached, the following actions are performed by the inverter:
1. The monitoring of the actual speed is deactivated.
2. The drive accelerates to the set speed
3. The status LED SS1 changes from flashing to on state.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-111
Functions
8.18 Fail-safe functions

When SS1 is deactivated after the "minimum speed for standstill detection" (P9682/P9882)
is reached, the following actions are performed by the inverter:
1. STO is deactivated.
2. The forced dynamisation procedure is carried out (if parameterised by p9601 and p9801).
3. The forced dynamisation timer (p9660) is reset to the value in p9659 (if the forced
dynamisation procedure was carried out successfully).
4. The mechanical brake (if fitted) is opened, if not closed by holding brake function
(P1215).
5. The status LED SS1 changes from flashing to on state.
6. The status LED ES is switched off.

Note
The state of the fail-safe functions is announced by r9772.

Note
The fail-safe function SS1 should not be activated during following processes are active:
• Search process in flying restart
• Motor data identification
• Speed control optimisation
It is recommended not to use the torque contol (P1300 = 22, 23 or P1501 > 0) as a control
mode for the fail-safe function SS1.

Caution
Reaction time
The reaction time for a SS1 is 20 ms.
Fault reaction time
An internal failure during a SS1, which leads to a LSTO, will be detected within the time
specified in "Fault reaction time" of section "Limiting values for SS1 and SLS".
The overall reaction time is the sum of reaction time and fault reaction time.

Control Units CU240S

8-112 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.18 Fail-safe functions

Caution
The frequency setpoint can increase related to the following functions
• PID Trim
• Vdc max controller
• Slip compensation
• Resonance damping
• Imax
As the frequency is monitored after adding these values, this increasement should be taken
into account by the user when parameterising the safe frequency envelope.
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deactivated and has no influence to the frequency setpoint at the latest 1 s after the fail-safe
function has been activated.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-113
Functions
8.18 Fail-safe functions

8.18.5 Safely-Limited Speed

Data

Parameter range: P0003, P0010

P09761
P9603/P9803, Bit 00, Bit 01 or Bit 07 (PROFIsafe)
P9799/P9899/P3900
P9690/P9890
P9691/P9891
P9692/P9892
Warnings A1691, A1692, A1696, A1699
Faults F1600, F1616

Description
The purpose of the Safely-Limited Speed (SLS) function is to monitor the speed of the motor
to ensure that it does not exceed the upper SLS limit set by parameters P9691 and P9891.
Should the upper SLS limit be exceeded a braking process will be initiated which is
monitored using the safe braking ramp function. If a stationary state is detected, the Safe
Torque Off (STO) will be initiated to bring the motor to a safe standstill. If the braking
functions fails, which is detected as a fault, then the Latched Safe Torque Off (LSTO)
function is initiated and cannot be cleared without explicitly acknowledgment of the fault.
The SLS function can be intercepted by the following commands:
● Safe Torque Off (STO)
● OFF1 (only SLS Mode 2)
● OFF2
● OFF3 (only SLS Mode 2)
However, the reaction of the system to the standard OFF commands may produce
unpredictable results. If the standard OFF commands are to be used with the fail-safe
functions, the interaction of the commands on the system are automatically monitored in the
background by the fail-safe system (i.e. the commands, which are not fail-safe, cannot cause
the inverter to accelerate in an unsafe way as the LSTO function will be triggered
automatically).

Control Units CU240S

8-114 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.18 Fail-safe functions

Note
The fail-safe function SLS should not be activated during following processes are active:
• Search process in flying restart
• Motor data identification
• Speed control optimisation
It is recommended not to use the torque contol (P1300 = 22, 23 or P1501 > 0) as a control
mode for the fail-safe function SLS.

Caution
Reaction time
The reaction time for a SLS is 20 ms.
Fault reaction time
An internal failure during a SLS, which leads to an LSTO, will be detected within the time
specified in "Fault reaction time" of section "Limiting values for SS1 and SLS".
The overall reaction time is the sum of reaction time and fault reaction time.

Modes of behavior
The SLS function has three modes of behavior giving the user a choice of functionality to suit
their specific application. These modes of behavior of the SLS function are controlled by
setting the required values in parameters P9692 and P9892.

Caution
Due to monitoring reasons, the so called "accuracy limit for SLS" with a value of 1 Hz is set.
If - in SLS mode - the actual frequency under-runs this value, an STO is triggered.

Warning
If due to dynamic loads the frequency runs above the SLS limit (P9691/P9891) an LSTO is
triggered; if it falls below the accuracy limit an STO is triggered. Therefore when designing
the plant, dynamic load changes must be taken into account to prevent unintented activation
of fail-safe functions.
Furthermore the acceptance test should be performed under worst-case load conditions.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-115
Functions
8.18 Fail-safe functions

SLS Mode 0
P9692 = P9892 = 0
If, after initiation of SLS, the motor exceeds the upper SLS limit set with P9691 and P9891,
then the latched STO (LSTO) function is initiated to bring the motor to a standstill.
If the motor speed is below the upper SLS limit, all control signals that can affect the speed
of the motor are blocked. No external control of the motor speed is possible.
Once the motor is locked at its present speed, if the motor again falls below this speed (for
example additional load on the motor), it is not interpreted as a fault condition and no action
is taken. See the following table.
During SLS mode 0 is active the the fault reaction time for a STO is given according to the

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formular  )DFW

Control Units CU240S

8-116 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.18 Fail-safe functions

Case 1: SLS monitoring (p9691/p9891) > Frequency setpoint > SLS setpoint
Initiation of SLS => • Ramp monitoring activated
• SLS-LED flashing
• ES-LED on
• Frequency setpoint deactivated
• Ramp down with SS1 to SLS setpoint
When SLS is reached => • SLS monitoring on
• Frequency setpoint inactive
Deactivation of SLS => • Ramp monitoring off
• Frequency setpoint activated
• SLS monitoring off
• SLS-LED and ES-LED off
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Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-117
Functions
8.18 Fail-safe functions

Case 2: SLS setpoint > Frequency setpoint > standstill detection (p9682/p9882)
Initiation of SLS => • Ramp monitoring activated
• SLS-LED flashing
• ES-LED on
• Frequency setpoint deactivated
When SLS is reached => • SLS monitoring on
• Frequency setpoint inactive
Deactivation of SLS => • Ramp monitoring off
• Frequency setpoint activated
• SLS monitoring off
• SLS-LED and ES-LED off
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Control Units CU240S

8-118 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.18 Fail-safe functions

Case 3: Standstill detection (p9682/p9882) > Frequency setpoint > accuracy limit
Initiation of SLS => • Ramp monitoring activated
• SLS-LED flashing
• ES-LED on
• Frequency setpoint deactivated
When SLS is reached => • SLS monitoring on
• Frequency setpoint inactive
Deactivation of SLS => • Ramp monitoring off
• Frequency setpoint activated
• SLS monitoring off
• SLS-LED and ES-LED off
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Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-119
Functions
8.18 Fail-safe functions

For case 1 to case 3:

If speed increases SLS tolerance (e.g. due to trim or slip compensation) =>
• LSTO is triggered
• SF-LED on
• STO-LED off
• SS1-LED off
• SLS-LED off
Deactivation of SLS =>
• No action
To start again, LSTO must be acknowledged and a new on command
is necesarry to ramp up to frequency setpoint.
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Control Units CU240S

8-120 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.18 Fail-safe functions

Case 4: accuracy limit > Frequency setpoint

Initiation of SLS => • Ramp monitoring activated
• STO activated
• SLS-LED flashing
• ES-LED on
• Frequency setpoint deactivated
Deactivation of SLS => • Ramp monitoring off
• Frequency setpoint activated
• SLS monitoring off
• SLS-LED on
• ES-LED off
To start again, STO must be acknowledged and a new on command is
necesarry to ramp up to frequency setpoint.
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Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-121
Functions
8.18 Fail-safe functions

Case 5.1: Frequency setpoint > SLS monitoring (p9691/p9891) primary fault
Initiation of SLS => • Ramp monitoring activated
• SLS-LED flashing
• Frequency setpoint deactivated
• Ramp down with SS1 to standstill
detection
When standstill detection is • Frequency setpoint inactive
reached => • LSTO activated
Deactivation of SLS => • No action
• To start again, LSTO must be
acknowledged and a new on command is
necesarry to ramp up to frequency
setpoint.
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Control Units CU240S

8-122 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.18 Fail-safe functions

Case 5.2: Frequency setpoint > SLS monitoring (p9691/p9891) secondary fault
Initiation of SLS => • Ramp monitoring activated
• SLS-LED flashing
• Frequency setpoint deactivated
• Ramp down with SS1 to standstill
detection
When actual frequency runs • Frequency setpoint inactive
above SS1 ramp down • LSTO activated immediately
monitoring before standstill
detection is reached
Deactivation of SLS => • No action
• To start again, LSTO must be
acknowledged and a new on command is
necesarry to ramp up to frequency
setpoint.
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Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-123
Functions
8.18 Fail-safe functions

Note
It must be observed that with detecting a fault during the fail-safe function SLS mode 0 is
active, first it will be tryed to brake the drive at the safe brake ramp.
The brake time is determined by parameters P9681/P9881. As the drive at this time is in a
fail-safe mode, it is not possible to interrupt the braking ramp by an other function (e.g. STO).
It is recommended to parameterise the shortest possible ramp time for the application.

SLS Mode 1
P9692 = P9892 = 1
In addition to the speed limit set in parameters P9691 and P9891, a further SLS setpoint can
be set in parameters P9690 and P9890. This additional SLS setpoint is used to set the
speed of the motor to a specific frequency, instead of bringing the motor to a standstill.
If the actual speed of the motor falls below the SLS setpoint set in P9690 and P9890, the
motor is allowed to run at that speed. See the following table.

Control Units CU240S

8-124 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.18 Fail-safe functions

Case 1: SLS monitoring (p9691/p9891) > Frequency setpoint > SLS setpoint
Initiation of SLS => • Ramp monitoring activated
• SLS-LED flashing
• Frequency setpoint deactivated
• Ramp down with SS1 to SLS setpoint
When SLS is reached => • SLS monitoring on
• ES-LED on
• Frequency setpoint inactive
Deactivation of SLS => • Ramp monitoring off
• SLS monitoring off
• SLS-LED and ES-LED off
• activate freq. setpoint and ramp to freq.
setpoint
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Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-125
Functions
8.18 Fail-safe functions

Case 2: SLS setpoint > Frequency setpoint > standstill detection (p9682/p9882)
Initiation of SLS => • Ramp monitoring activated
• SLS-LED flashing
• Frequency setpoint deactivated
When SLS is reached => • SLS monitoring on
• ES-LED on
• Frequency setpoint inactive
Deactivation of SLS => • Ramp monitoring off
• SLS monitoring off
• SLS-LED and ES-LED off
• activate freq. setpoint and ramp to freq.
setpoint
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Control Units CU240S

8-126 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.18 Fail-safe functions

Case 3: standstill detection (p9682/p9882) > Frequency setpoint > accuracy limit
Initiation of SLS => • Ramp monitoring activated
• SLS-LED flashing
• Frequency setpoint deactivated
When SLS is reached => • SLS monitoring on
• ES-LED on
• Frequency setpoint inactive
Deactivation of SLS => • Ramp monitoring off
• SLS monitoring off
• SLS-LED and ES-LED off
• activate freq. setpoint and ramp to freq.
setpoint
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Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-127
Functions
8.18 Fail-safe functions

Case 4: accuracy limit > Frequency setpoint

Initiation of SLS => • Ramp monitoring activated
• SLS-LED flashing
• Frequency setpoint deactivated
When SLS is reached => • SLS monitoring on
• ES-LED on
• Frequency setpoint inactive
Deactivation of SLS => • Ramp monitoring off
• SLS monitoring off
• SLS-LED and ES-LED off
• activate freq. setpoint and ramp to freq.
setpoint
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Control Units CU240S

8-128 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.18 Fail-safe functions

Case 5: Frequency setpoint > SLS monitoring (p9691/p9891)

Initiation of SLS => • Ramp monitoring activated
• SLS-LED flashing
• Frequency setpoint deactivated
When SLS is reached => • SLS monitoring on
• ES-LED on
• Frequency setpoint inactive
Deactivation of SLS => • No action
• To start again, LSTO must be
acknowledged and a new on command
is necesarry to ramp up to frequency
setpoint.
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Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-129
Functions
8.18 Fail-safe functions

Case 6: SLS setpoint > Frequency setpoint > standstill detection (p9682/p9882)
Initiation of SLS => • Ramp monitoring activated
• SLS-LED flashing
• Frequency setpoint deactivated
When actual frequency runs • LSTO activated immediately
above SLS monitoring
Deactivation of SLS => • No action
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acknowledged and a new on command
is necesarry to ramp up to frequency
setpoint.
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Control Units CU240S

8-130 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.18 Fail-safe functions

SLS Mode 2
P9692 = P9892 = 2

Warning
Safe brake ramp not actived
Mode 2 means that the safe brake ramp is not activated, therefore it is the users
responsibility to ensure that the motor is ramped down to or below the SLS setpoint.

In Mode 2, only the monitoring ramp (envelope) is activated, the safe brake ramp will is not
active.
If the motor speed exceeds the upper SLS limit set in P9691 and P9891, the motor must be
ramped down using an external control channel (for example, a PLC, potentiometer or USS
etc.). If the control channel tries to set the speed of the motor to exceed the upper SLS limit,
this will be interpreted as a fault condition and the motor will be stopped and latched. To start
the motor again, the fault condition needs to be explicitly acknowledged. See the following
table.
Fault reactions according the selected SLS mode 2

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-131
Functions
8.18 Fail-safe functions

Case 1: Frequency setpoint > SLS monitoring

Initiation of SLS => • SLS monitoring activated
• Frequency setpoint deactivated
• SLS-, STO- and SS1-LED off
• LSTO is triggered
Deactivation of SLS => • SLS monitoring off
• SLS-LED off
• To start again, LSTO must be
acknowledged and a new on command
is necesarry to ramp up to frequency
setpoint.
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Control Units CU240S

8-132 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.18 Fail-safe functions

Case 2: SLS monitoring > Frequency setpoint > accuracy limit

Initiation of SLS => • SLS monitoring activated
• SLS-LED flashing
Deactivation of SLS => • SLS monitoring off
• SLS-LED off
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Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-133
Functions
8.18 Fail-safe functions

Case 3: SLS monitoring > Frequency setpoint

Initiation of SLS => • SLS monitoring activated
• SLS-LED flashing
If frequeny setpoint falls below accuracy limit, an LSTO is triggered
immediately
Deactivation of SLS => • SLS monitoring off
• SLS-LED off
• To start again, LSTO must be
acknowledged and a new on command
is necesarry to ramp up to frequency
setpoint.
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8-134 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.18 Fail-safe functions

Case 4: SLS monitoring > Frequency setpoint

Initiation of SLS => • SLS monitoring activated
• SLS-LED flashing
If frequeny setpoint runs above SLS monitoring an STO is triggered
immediately
Deactivation of SLS => • SLS monitoring off
• SLS-LED off
• To start again, STO must be
acknowledged and a new on command
is necesarry to ramp up to frequency
setpoint.
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Note
Inside SLS tolerance means a value between upper and lower SLS limit.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-135
Functions
8.18 Fail-safe functions

Caution
In SLS modes 0 and 1, the frequency setpoint can increase related to the following functions
• PID Trim
• Vdc max controller
• Slip compensation
• Resonance damping
• Imax
As the frequency is monitored after adding these values, this increasement should be taken
into account by the user when parameterising the safe frequency envelope.
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deactivated and has no influence to the frequency setpoint at the latest 1 s after the fail-safe
function has been activated.

8.18.6 Safe Brake Control

Data

Parameter range: P0003, P0010

P09761
P9601/P9801, P1215, P3046
P9602/P9802
P9799/P9899/P3900
Warnings A1691, A1692, A1696, A1699
Faults F1600, F1616

Description
The Safe Brake Control function (SBC) is to create a fail-safe signal to control an
electromechanical motor brake.

Control Units CU240S

8-136 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.18 Fail-safe functions

Caution
The connection between the brake on the motor and the Safe Brake Control Relay is
supervised at forced dynamisation but not during operation.

Prerequisite: P1215 = 1 and the optional Safe Brake Control Relay

To activate the Safe Brake Control function, the following parameters must be set: P9602 =
P9802 = 1 (factory setting is 0).
In case of P9602 = P9802 = 1 a test signal regarding the signal to the Safe Brake Control is
created. This tests the signal not the brake itself.
This test signal does not interfere with the normal function of the mechanical brake. If the
mechanical brake is fitted and the test fails, a fault condition will be indicated by the inverter.

Note
When carrying-out the forced dynamisation, the shutdown paths of the motor brake are also
tested. This results a brief opening command (2 ms to 28 ms) in the motor brake.
The mechanical part of the brake generally requires longer than 30 ms to open. This means
that this dynamic operation generally has no influence on the motor shaft itself. However it is
the user's responsibility to use brakes with opening times > 30 ms.

The SBC will be activated in the following cases:

● STO/LSTO
● SS1
The SBC state is indicated in P9772.14. If SBC is disabled by P9602 = P9802 = 0 then
P9772.14 is set to 0 (brake open) even if the brake is closed from a non-safe brake control
(e.g. MHB).

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-137
Functions
8.19 Closed-loop Vdc control

8.19 Closed-loop Vdc control

Overview
In addition to DC, compound and dynamic braking, for the SINAMICS G120 it is possible to
prevent a DC link overvoltage condition using the closed-loop Vdc controller. With this
technique, the output frequency is automatically modified during operation using the closed-
loop Vdc controller so that the motor doesn't go too far into the regenerative mode.
Using the Vdc controller, it is also possible to prevent the inverter from being shut down
(tripped) during brief line supply dips – which cause a DC link undervoltage condition. Also in
this case, the output frequency is automatically modified by the Vdc controller during
operation. Contrary to an overvoltage condition, in this case the motor is operated with
increased regenerative operation in order to support and buffer the DC link voltage.

DC link overvoltage
● Cause:
The motor regenerates and feeds too much energy back into the DC link.
● Remedy:
The DC link voltage is further reduced using the Vdc_max controller by reducing the
regenerative torque down to zero.

DC link undervoltage
● Cause:
Line supply voltage failure or dip (blackout or brownout)
● Remedy:
A regenerative torque is entered for the operational motor which compensates the
existing losses and therefore stabilizes the voltage in the DC link. This technique is
carried-out using the Vdc_min controller and is known as kinetic buffering.

Control Units CU240S

8-138 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.19 Closed-loop Vdc control

8.19.1 Vdc_max controller

Data

Parameter range: P1240, r0056 bit 14

r1242, P1243
P1250 – P1254
Warnings: A0502, A0503, A0910, A0911
Faults: F0002
Function chart number: FP4600

Description
A brief regenerative load can be handled using this function (enabled using P1240) without
the inverter being shut down (tripped) with fault message F0002 ("DC link overvoltage"). In
this case, the frequency is controlled (closed-loop) so that the motor doesn't go too far into
regenerative operation.
If the inverter regenerates too much when braking the machine due to a fast ramp-down time
P1121, then the braking ramp/ramp time is automatically extended and the inverter is
operated at the DC link voltage limit r1242 (see figure below). If the DC link again falls below
the threshold r1242, then the Vdc_max controller withdraws the extension of the braking
ramp.

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Figure 8-73 Vdc_max controller

On the other hand, if the Vdc_max controller increases the output frequency (e.g. for a
steady-state regenerative load), then the Vdc_max controller is disabled by an internal
inverter monitoring function and the warning A0910 is output. If the regenerative load
continues, the inverter is protected using fault F0002.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-139
Functions
8.19 Closed-loop Vdc control

In addition to controlling the DC link (closed-loop), the Vdc_max controller supports the
stabilizing processes of the speed at the end of an acceleration phase. This is especially the
case if there is an overshoot and the motor therefore briefly goes into regenerative operation
(damping effect).

Note
If the DC link voltage exceeds the power-on threshold r1242 (switch-on level of Vdc_max.) of
the Vdc_max controller in the "Ready" state, then the Vdc_max controller is de-activated and
warning A0910 is output.
Cause: The line supply voltage does not match the application situation
Remedy: Refer to parameters P1254 and P0210.
If, in the "Run" state, the DC link voltage exceeds the power-on threshold r1242 and if the
Vdc_max controller output is limited by parameter P1253 for approx. 200 ms, then the
Vdc_max controller is de-activated and the warning A0910 and, where relevant, fault F0002
are output.
Cause: Line supply voltage P0210 or ramp-down time P1121 too low
The moment of inertia of the motor load is too high
Remedy: Refer to parameters P1254, P0210, P1121
Use a braking resistor

Control Units CU240S

8-140 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.19 Closed-loop Vdc control

8.19.2 Kinetic buffering

Data

Parameter range: P1240

r0056 bit 15
P1245, r1246, P1247
P1250
P1256, P1257
Warnings: A0503
Faults: F0003
Function chart number: FP4600

Description
Brief line supply failures can be buffered using the kinetic buffering function (enabled using
P1240). Line supply failures are buffered using the kinetic energy (i.e. moments of inertia) of
the motor load. In this case the prerequisite is that the motor load has a sufficiently high
moment of inertia - i.e. has sufficient kinetic energy.
Using this technique, the frequency is controlled (closed-loop), so that energy is fed to the
inverter from the regenerating motor thus covering the system losses. The losses during the
line supply failure still remain which means that the motor speed decreases. When using
kinetic buffering it has to be taken into consideration that the motor speed is reduced.

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Figure 8-74 Kinetic buffering (Vdc_min controller)

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-141
Functions
8.19 Closed-loop Vdc control

When the line supply returns, the energy feed is again from the line side and the output
frequency of the inverter returns to the selected setpoint along the ramp defined by the
ramp-function generator.

Note
When the DC link voltage falls below the minimum VDC_min, fault F0003 "Undervoltage" is
output and the inverter is shut down. The shutdown threshold VDC_min depends on the
inverter type and line supply voltage.
For the SINAMICS G120 the DC link undervoltage shutdown threshold is 430 V.

Control Units CU240S

8-142 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.20 Positioning ramp down

8.20 Positioning ramp down

Data

Parameter range: P2480 – r2489

Warnings: -
Faults: -
Function chart number: -

Description
The positioning ramp down can be used for applications where it is necessary that a residual
distance is moved-through up to the stop dependent on an external event (e.g. BERO
switch). In this case, the SINAMICS G120 generates a continuous braking ramp by selecting
OFF1 depending on the actual load speed and velocity. The motor is then stopped and
positioned along this braking ramp (see figure below).

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Figure 8-75 Positioning ramp down

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-143
Functions
8.20 Positioning ramp down

In this case, the remaining distance P2488 moved through must be entered, referring to the
load. In order to carry-out the residual distance calculation on the load side, the mechanical
arrangement of the axis (gearbox ratio, linear or rotary axis) must be appropriately
parameterized (see figure below).

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Using this data, SINAMICS G120 calculates the ratio between the distance and the motor
revolutions and can therefore consider the movement on the load side.

Note
The "Switch-off frequency" (P2167) can have an influence on the final positioning result.

Control Units CU240S

8-144 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.21 General monitoring functions and messages

8.21 General monitoring functions and messages

Data

Parameter range: P2150 … P2180

r0052, r0053, r2197, r2198
Warnings: -
Faults: -
Function chart number: FP4100, FP4110

Description
The SINAMICS G120 has an extensive range of monitoring functions and messages which
can be used for open-loop process control. The control can either be implemented in the
inverter or using an external control (e.g. PLC). The interlocking functions in the inverter as
well as the output of signals for external control are implemented using BICO technology.
The status of the individual monitoring functions and messages are emulated in the following
CO/BO parameters:

r0019 CO/BO: OP control word

r0050 CO/BO: Active command data set
r0052 CO/BO: Status word 1
r0053 CO/BO: Status word 2
r0054 CO/BO: Control word 1
r0055 CO/BO: Supplementary (additional) control word
r0056 CO/BO: Status word – closed-loop motor control
r0403 CO/BO: Encoder status word
r0722 CO/BO: Status, digital inputs
r0747 CO/BO: Status, digital outputs
r1407 CO/BO: Status 2 – closed-loop motor control
r2197 CO/BO: Messages 1
r2198 CO/BO: Messages 2
Frequently used monitoring functions/messages including parameter number and bit are
shown in the table below.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-145
Functions
8.21 General monitoring functions and messages

Table 8-31 Extract of monitoring functions and messages

Functions/states Parameter/bit number Function chart

Inverter ready 52.0 -
Inverter ready to run 52.1 -
Inverter running 52.2 -
Inverter fault active 52.3 -
OFF2 active 52.4 -
OFF3 active 52.5 -
On inhibit active 52.6 -
Inverter warning active 52.7 -
Deviation setpoint – actual value 52.8 -
PZD control 52.9 -
|f_act| >= P1082 (f_max) 52.10 -
Warning: Motor current limit 52.11 -
Brake active 52.12 -
Motor overload 52.13 -
Motor runs right 52.14 -
Inverter overload 52.15 -
DC brake active 53.0 -
Ramping finished 53.9 -
PID output R2294 == P2292 (PID_min) 53.10 FP5100
PID output R2294 == P2291 (PID_max) 53.11 FP5100
f_act ≧ P1080 (f_min) 53.2, 2197.0 FP4100
f_act ≦ P2155 (f_1) 53.5, 2197.1 FP4110
f_act > P2155 (f_1) 53.4, 2197.2 FP4110
f_act > zero 2197.3 FP4110
f_act >= setpoint (f_set) 53.6, 2197.4 -
|f_act| <= P2167 (f_off) 53.1, 2197.5 FP4100
|f_act| >= P1082 (f_max) 2197.6 -
f_act == setpoint (f_set) 2197.7 FP4110
i_act ≧ P2170 53.3, 2197.8 FP4100
Vdc_act < P2172 53.7, 2197.9 FP4110
Vdc_act > P2172 53.8, 2197.10 FP4110
No-load operation 2197.11 -
|f_act| <= P2157 (f_2) 2198.0 -
|f_act| > P2157 (f_2) 2198.1 -
|f_act| <= P2159 (f_3) 2198.2 -
|f_act| > P2159 (f_3) 2198.3 -
|f_set| < P2161 (f_min_set) 2198.4 -
f_set > 0 2198.5 -
Motor blocked 2198.6 -
Motor stalled 2198.7 -
|i_act r0068| < P2170 2198.8 FP4100

Control Units CU240S

8-146 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.21 General monitoring functions and messages

Functions/states Parameter/bit number Function chart

|m_act| > P2174 & setpoint reached 2198.9 -
|m_act| > P2174 2198.10 -
Load torque monitoring: Warning 2198.11 -
Load torque monitoring: Fault 2198.12 -

Note
On the OP the bit numbers are displayed in hex-format (0..9, A..F).

8.21.1 Load torque monitoring

Data

Parameter range: P2181 … P2192

r2198
Warnings: A0952
Faults: F0452
Function chart number: –

Description
This function allows the mechanical force transmission between the motor and motor load to
be monitored. Typical applications include, for example, pulley belts, flat belts or chains, or
pulleys for toothed wheels of motor-in and motor-out shafts which then transmit
circumferential velocities and circumferential forces (see figure below). The load torque
monitoring function can then detect whether the motor load is locked or the force
transmission has been interrupted.

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Figure 8-77 Shaft drive with flat belts

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-147
Functions
8.21 General monitoring functions and messages

For the load torque monitoring function, the actual frequency/torque characteristic is
compared with the programmed frequency/torque characteristic (refer to P2182 … P2190). If
the actual value lies outside the programmed tolerance bandwidth, then, depending on
parameter P2181, either warning A0952 or fault F0452 is generated. Parameter P2192 can
be used to delay the output of the warning or fault message. This avoids erroneous alarms
which could be caused by brief transient states (see figure below).

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Figure 8-78 Load torque monitoring (P2181 = 1)

The frequency/torque tolerance bandwidth is defined by the gray shaded area in the figure
below. The bandwidth is determined by the frequency values P2182 … P2184 including the
max. frequency P1082 and the torque limits P2186 … P2189. When defining the tolerance
bandwidth it should be ensured that a specific tolerance is taken into account in which the
torque values are allows to vary corresponding to the application.

Control Units CU240S

8-148 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.21 General monitoring functions and messages

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Figure 8-79 Frequency and torque tolerance bandwidth

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-149
Functions
8.22 Thermal motor protection and overload responses

8.22 Thermal motor protection and overload responses

Data

Parameter range: P0601 … P0640

P0344
P0350 … P0360
r0035
Warnings: A0511
Faults: F0011, F0015
Function chart number: –

Description
The SINAMICS G120 has a completely new integrated concept for thermal motor protection.
There are numerous possibilities of effectively protecting the motor but at the same time
ensuring high motor utilization. The basic philosophy of this innovative concept is to detect
critical thermal states, output warnings and initiate the appropriate responses. By responding
to critical states it is possible to operate the motor at the thermal power limit and to avoid,
under all circumstances, an immediate shutdown (where the inverter is tripped).

Control Units CU240S

8-150 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.22 Thermal motor protection and overload responses

Features
The protective concept (see figure below) distinguishes itself as a result of the following
individual features:
● Protection is effective without using any temperature sensor (P0601 = 0). The
temperatures of various locations in the motor are indirectly determined using a
temperature model.
● It is possible to evaluate temperature sensors. This has the advantage that after a line
supply failure, precise initial temperatures are immediately available. Both PTC sensors
(P0601 = 1) as well as KTY84 sensors (P0601 = 2) can be connected and evaluated.
● When using a KTY84 sensor, the inverter can be parameterized so that a sensor wire
breakage or short-circuit F0015 is detected and the system automatically changes-over to
the temperature model. This means that the inverter is not shut down (tripped) and
operation can continue.
● Selectable temperature warning thresholds P0604 (default: 130 ｰC) for operation with the
temperature model or KTY84 sensor. The inverter is shut down or the current reduced
depending on P0610 for a value of P0604 +10 %.
● Selectable responses P0610 which are to be initiated when the warning threshold is
exceeded in order to prevent an overload condition.
● The motor protection has been designed to be completely independent of the inverter
protection. Warning thresholds and responses for inverter protection must be separately
parameterized.
● Various data sets are taken into account in the model. The model is separately calculated
for each data set so that when changing-over between various motors the cooling of the
presently non-active (fed) motors are taken into account.

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Figure 8-80 Thermal motor protection

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-151
Functions
8.22 Thermal motor protection and overload responses

Temperature rise classes

In motor technology, temperature rise issues play a decisive role when dimensioning
electrical machinery. Different temperature limits apply for the various materials used in
electric motors. Depending on the insulating material being used, a differentiation is made
according to thermal classes (refer to the motor rating plate) with defined limit temperatures.
An excerpt from IEC85 is provided in the table below

Table 8-32 Extract from IEC85 thermal classes

Thermal Class Max. permissible temperature

Y 90 ｺC
A 105 ｺC
E 120 ｺC
B 130 ｺC
F 155 ｺC
H 180 ｺC
For the temperature model or the KTY84 sensor, the appropriate value ϑwarn must be
calculated and entered into parameter P0604 (temperature warning threshold, default:
130ｰC). The following applies:
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8.22.1 Thermal motor model

Description
The data, required for the thermal motor model, is estimated from the rating plate data
entered during the quick commissioning. This data permits reliable, stable operation for
standard Siemens motors. If required, parameter changes must be made for motors from
third-party manufacturers. We always recommend that an automatic motor data identification
run is made after quick commissioning so that the electrical equivalent circuit diagram data
can be determined. This allows a more precise calculation of the losses which occur in the
motor which has an impact on the accuracy of the thermal motor model.

Example
A stator resistance, which is parameterized to be too high, would result, in the model, higher
losses than in a real motor and an excessively high calculated motor temperature would be
displayed.
If changes are required in order to optimize the thermal model, then as a first step, the motor
weight (P0344) should be checked for plausibility. Generally, the motor weight is taken from
the Catalog data of the motor manufacturer. The thermal model can be further optimized by
adapting the standard overtemperatures for the stator iron P0626, the stator winding P0627
and the rotor P0628. The standard overtemperatures represent the steady-state
temperatures to be expected in rated operation with respect to the environment and are used
to estimate the thermal resistances. Generally, these overtemperatures are not listed in the
Catalog.

Control Units CU240S

8-152 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.22 Thermal motor protection and overload responses

The ambient temperature P0625 is another important parameter which influences the
precision of the thermal model.

8.22.2 Motor Temperature Identification after Restart

Data

Parameter range: P0621 … r0623

Warnings: –
Faults: –
Function chart number: –

Description
The thermal motor model can be used to calculate the motor temperature. Not only this it
can be also used to optimize the control loops for closed-loop vector control and for
temperature monitoring. A KTY84 sensor is then no longer required for temperature sensing.
After the power supply (24 V) has been powered-down, the motor temperature - internally
calculated using the thermal motor model - is no longer available. The model then starts with
the ambient temperature value (P0625).
If the "Determining the motor temperature after motor start" function is active, the motor
temperature is detected by measuring the current after magnetization and the thermal motor
model is then pre-assigned this value.
Parameter P0621 is used to select when the function is active:
P0621 = 0: The function is de-activated. The thermal motor model then uses the ambient
temperature value (P0625).
P0621 = 1: The motor temperature is determined once when the motor first starts after the
power supply has been switched-in. This setting is used for standard motors.
P0621 = 2: For this setting, a new temperature measurement is carried-out each time the
motor starts. This technique is practical for motors whose thermal behavior differs from
standard motors. In these cases, it is possible that the thermal model is too inaccurate and
would supply larger deviations.

Note
If a KTY84 sensor is being used and is functional, then the temperature of the sensor is used
in all settings of parameter P0621. In this case, the temperature is not measured using the
stator resistance.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-153
Functions
8.22 Thermal motor protection and overload responses

Procedure when measuring the temperature

After the power supply is switched-in and an ON command is issued, the motor is first
magnetized. If the "Determine the motor temperature after motor start" function has still not
been activated, the motor immediately starts to rotate after the ON command has been
issued. If this function is activated, the system waits until magnetization has been completed
and until the motor current is constant. The measuring intervals for this procedure are
specified using parameter P0622. The measurement itself is made if the current remains
constant over one measuring period within a certain tolerance bandwidth. Generally, several
measuring intervals are required. If the current is constant, then the actual current is
measured and the actual winding resistance is determined. This is then entered into
parameter R0623.
For a cold motor, this must approximately corresponds to the value of parameter P0350 of
the motor data identification; it must be appropriately higher for a motor in the warm
condition (at 130 ｰC approximately 150 %).

Note
In the following cases, the motor temperature is not measured:
• V/f operation
• Fault when measuring the current, e.g. the current isn’t sufficiently constant
• For a flying restart the speed is too high
In these cases - when first accelerating after the power supply has been powered-up - an
average temperature value is used (approx. 47 °C). When the motor starts without powering-
down the power supply, the temperature does not change.

8.22.3 Temperature sensors

Data

Parameter range: P0601

Warnings: -
Faults: -
Function chart number: -

Description
When the motor is operated below the rated speed the cooling effect of the shaft-mounted
fan is reduced. As a result, for most motors when continually operated at lower frequencies,
the power has to be reduced. Under these conditions, motor protection against overheating
can only be guaranteed if either a temperature sensor (PTC or KTY84 sensor) is integrated

Control Units CU240S

8-154 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.22 Thermal motor protection and overload responses

in the motor and is connected to the control terminals (see figure below) of the SINAMICS
G120 or the motor temperature model was determined.

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Figure 8-81 Connecting a temperature sensor

Note
In order to avoid EMC noise from being coupled-in to the motor/inverter electronics the
associated disturbances is not permissible to use free conductors in the motor cable to
connect the temperature sensor to the motor/inverter.
The temperature sensor must be connected to the motor/inverter using a separate cable (if
at all possible, this cable should be shielded).

With PTC temperature sensor (P0601 = 1)

The PTC is connected to the control terminals 14 and 15 of the SINAMICS G120. PTC
monitoring is activated with the parameter setting P0601 = 1. If the resistance value,
connected at the terminals, is less than 1500 Ω, then neither alarm nor fault is generated. If
this value is exceeded, the inverter outputs alarm A0511 and fault F0011. The resistance
value where the alarm and fault are output is not less than 1000 Ω and not more than
2000 Ω.

Figure 8-82 PTC characteristics for 1LG/1LA motors

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-155
Functions
8.22 Thermal motor protection and overload responses

With KTY84 temperature sensor (P0601 = 2)

The KTY84 must be connected so that the diode is in the conductive direction. This means
that the anode is connected to terminal 14 and the cathode to terminal 15. If the temperature
monitoring function is activated with the setting P0601 = 2, the temperature of the sensor
(i.e. of the motor windings) is written into parameter r0035. The threshold temperature ϑtrip of
the motor can now be set using the warning threshold, motor overtemperature ϑwarn
(parameter P0604) (the factory setting is 130 ｰC). The following applies:
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3  ˽ZDUQ  
 

Figure 8-83 KTY84 characteristics for 1LG/1LA motors

Wire breakage or short-circuit

If the circuit between the inverter and PTC or KTY84 sensor is interrupted or there is a short-
circuit, the inverter is shut down (tripped) and fault F0015 is displayed.

Control Units CU240S

8-156 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.23 Power Module protection

8.23 Power Module protection

8.23.1 General overload monitoring

Data

Parameter range: P0640, r0067, r1242, P0210

Warnings: A0501, A0502, A0503
Faults: F0001, F0002, F0003, F0020
Function chart number: -

Description
Just the same as for motor protection, the SINAMICS G120 provides extensive protection for
the power components. This protection concept is sub-divided into two levels:
● Warning and response
● Fault and shutdown
Using this concept, a high utilization of the power module components can be achieved
without the inverter being immediately shut down.
The monitoring thresholds for the faults and shutdowns are permanently saved in the
inverter and cannot be changed by the user. On the other hand, the threshold levels for
"Warning and response" can be modified by the user to optimize the system. These values
have default settings so that the "Fault and shutdown" thresholds do not respond.

8.23.2 Power module thermal monitoring

Data

Parameter range: P0290 … P0294

r0036 … r0037
Warnings: A0504, A0505
Faults: F0004, F0005, F0012, F0022
Function chart number: -

Description
Similar to motor protection, the main function of the thermal power module monitoring is to
detect critical states. Parameterizable responses are provided for the user which allows the
motor system to still be operated at the power limit avoiding immediate shutdown. However,

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-157
Functions
8.23 Power Module protection

the possibilities of assigning parameters only involves interventions below the shutdown
threshold which cannot be changed by users.
The SINAMICS G120 has the following thermal monitoring functions:
● i2t monitoring
The i2t monitoring is used to protect components which have a long thermal time constant
in comparison to the semiconductors. An overload with reference to i2t is present if the
inverter utilization r0036 indicates a value greater than 100 % (utilization as a % refers to
rated operation).
● Heatsink temperature
The heatsink temperature of the power semiconductors (IGBT) is monitored and
displayed in r0037[0].
● Chip temperature
Significant temperature differences can occur between the junction of the IGBT and the
heatsink. These differences are taken into account by the chip temperature monitoring
and are displayed in r0037[1].
When an overload occurs regarding one of these three monitoring functions, initially, a
warning is output. The warning threshold P0294 (i2t monitoring) and P0292 (heatsink
temperature and chip temperature monitoring) can be parameterized relative to the
shutdown values.

Example
The warning threshold P0292 for the temperature monitoring (chip/heatsink temperature) is
set to 15 ｰC in the factory. This means that warning A0504 is output 15 ｰC below the
shutdown threshold.
At the same time that the warning is output, the parameterized responses are initiated using
P0290 (default: P0290 = 2). Possible responses include:
● Reducing the pulse frequency (P0290 = 2 or 3)
This is an extremely effective method to reduce losses in the power module, as the
switching losses represent a very high proportion of the overall losses. In many
applications, a temporary reduction of the pulse frequency can be tolerated in favor of
maintaining the process
Disadvantage
The current ripple is increased when the pulse frequency is reduced. This can result in an
increase of the torque ripple at the motor shaft (for low moments of inertia) and an increase
in the noise level. When the pulse frequency is reduced this has no influence on the dynamic
response of the current control loop as the current control sampling time remains constant!
● Reducing the output frequency (P0290 = 0 or 2)
This is advantageous if it is not desirable to reduce the pulse frequency or if the pulse
frequency is already set to the lowest level. Further, the load should have a characteristic
similar to that of a fan, i.e. a square-law torque characteristic for decreasing speed. When
the output frequency is reduced, this significantly reduces the inverter output current and
in turn reduces the losses in the power module.
● No reduction (P0290 = 1)
This option should be selected if neither a reduction in the pulse frequency nor a
reduction in the output current is being considered. In this case, the inverter does not
change its operating point after the warning threshold has been exceeded so that the
motor can continue to be operated until the shutdown values are reached. After the
shutdown threshold has been reached, the inverter shuts down (trips) with fault F0004.

Control Units CU240S

8-158 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.23 Power Module protection

The time which expires up to shutdown is however not defined and depends on the
magnitude of the overload. Only the warning threshold can be changed in order to obtain
an earlier warning and, if required, externally intervene in the motor process (e.g. by
reducing the load, lowering the ambient temperature).

Note
If the inverter fan fails, this would be indirectly detected by the measurement of the
heatsink temperature.
A wire breakage or short circuit of the temperature sensor(s) is also monitored.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-159
Functions
8.24 Open-loop and closed-loop control

8.24 Open-loop and closed-loop control

Overview
There are several open-loop and closed-loop techniques for closed-loop speed and torque
control for inverters with induction and synchronous motors. These techniques can be
roughly classified as follows:
● V/f characteristic control (known as: V/f control)
● Field-orientated closed-loop control technique (known as: Vector control)
The field-orientated control technique – Vector control – can be further sub-divided into two
groups:
● Vector control without speed feedback (sensorless Vector control (SLVC))
● Vector control with speed feedback (Vector control (VC))
These techniques differ from one another both regarding the control ability and in the
complexity of the technique, which in turn are obtained as a result of the requirements
associated with a particular application. For basic applications (e.g. pumps and fans), to a
large extent, V/f control is used. Vector control is mainly used for sophisticated applications
(e.g. winders), where a good control and behavior in noisy conditions are required regarding
the speed and torque. If these requirements are also present in the range from 0 Hz to
approx. 1 Hz, then the speed/torque accuracy without encoder is not sufficient. In this case,
Vector control with speed feedback must be used.

8.24.1 V/f control

Data

Parameter range: P1300

P1310 … P1350
Warnings: -
Faults: -
Function chart number: FP6100

Description
The V/f characteristic represents the simplest control technique. In this case the stator
voltage of the induction motor or synchronous motor is controlled proportionally to the stator
frequency. This technique has proven itself for a wide range of "basic" applications, such as
● Pumps, fans
● Belt motors
and similar processes.
The goal of V/f control is to keep the flux Φ constant in the motor. In this case, this is
proportional to the magnetizing current Iμ and the ratio between voltage V and frequency f.

Control Units CU240S

8-160 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.24 Open-loop and closed-loop control

Φ ~ Iμ ~ V/f
The torque M, developed by induction motors, is proportional to the product (precisely the
Vectorial product Φ x I) of flux and current.
M~Φ*I
In order to generate the highest possible torque from a given current, the motor must operate
with a constant flux which is as high as possible. In order to keep the flux Φ constant, when
frequency f changes, the voltage V must be changed in proportion so that a constant
magnetizing current Iμ flows. The V/f characteristic control is derived from these basic
principles.

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Figure 8-84 Operating ranges and characteristics of an induction motor when fed from an inverter

There are several versions of the V/f characteristic as shown in the table below.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-161
Functions
8.24 Open-loop and closed-loop control

Table 8-33 V/f characteristics (parameter P1300)

Parameter Significance Use/property

value
9
0 Linear Standard case
characteristic 9Q

3 

I
 IQ

1 FCC Can give a more efficient and better load response than other V/f
modes because the FCC characteristic automatically compensates
the voltage losses of the stator resistance for static (steady-state) or
dynamic loads (flux current control FCC). This is used especially for
small motors which have a relatively high stator resistance.
2 Square-law This is a characteristic which
characteristic takes into consideration the 9

torque characteristic of the 9Q

motor load (e.g. fan/pump):

a) Square-law characteristic
(f2 characteristic)
b) Energy saving as the 3 

lower voltage also results  IQ

I

in lower currents and

losses.
9

3 Programmable Characteristic which takes into 9PD[

U

characteristic consideration the torque 9Q

3

characteristic of the
3 
3

motor/driven load (e.g. 3

synchronous motor).
3
3

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5 Application This is a characteristic which takes into consideration the special

adaptation technological issues of an application (e.g. textile applications),
a) Where the current limiting (Imax controller) only influences
the output voltage and not the output frequency, and
b) By inhibiting the slip compensation
6 Application This is a characteristic which takes into consideration the special
adaptation technological issues of an application (e.g. textile applications),
with FCC a) Where the current limiting (Imax controller) only influences
the output voltage and not the output frequency, and
b) By inhibiting the slip compensation
19 Independent The user can enter the output voltage of the inverter, independently
voltage input of the frequency, using a BICO parameter P1330 via the interfaces
(e.g. analog input → P1330 = 755).

Control Units CU240S

8-162 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.24 Open-loop and closed-loop control

8.24.1.1 Voltage boost

Data

Parameter range: P1310 … P1312

r0056 bit 05
Warnings: -
Faults: -
Function chart number: FP6100

Description
For low output frequencies, the V/f characteristics only output a low output voltage. Even at
low frequencies, the ohmic resistances of the stator winding play a role, which are neglected
when determining the motor flux in V/f control. This means that the output voltage can be too
low in order to:
● implement the magnetization of an induction motor,
● to hold the load
● to equalize losses (ohmic losses in the winding resistances) in the system or
● to provide a breakaway/accelerating/braking torque.
The output voltage can be increased (boosted) in the SINAMICS G120 using the parameters
as shown in the table below.

Note
Especially at low frequencies, the motor temperature is additionally increased as a result of
the voltage boost (the motor overheats)!
The voltage value at 0 Hz is determined from the product of rated motor current P0305,
stator resistance P0350 and the appropriate parameters P1310 … P1312.
Using very high boost values may cause the motor to stuck at a low frequency due to the
Imaxcontroller (very high boost may cause overcurrent failure).

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-163
Functions
8.24 Open-loop and closed-loop control

Table 8-34 Voltage boost

Parameter Voltage boost Explanation

P1310 Constant voltage The voltage boost is effective over the complete frequency rage whereby the
boost value continually decreases at high frequencies.
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accelerating or 9 /LQHDU9I
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Control Units CU240S

8-164 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.24 Open-loop and closed-loop control

Parameter Voltage boost Explanation

P1312 Voltage boost when The voltage boost is only effective when accelerating for the first time
starting (standstill)
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8.24.1.2 Slip compensation

Data

Parameter range: P1335

Warnings: -
Faults: -
Function chart number: FP6100

Description
In the V/f characteristic operating mode the motor frequency is always lower than the inverter
output frequency by the slip frequency fs. If the load (the load is increased from M1 to M2) is
increased with a constant output frequency, then the slip increases and the motor frequency
decreases (from f1 to f2). This behavior, typical for an induction motor, can be compensated
using slip compensation P1335. This therefore eliminates the speed reduction, caused by
the load, by boosting (increasing) the inverter output frequency (see figure below).

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-165
Functions
8.24 Open-loop and closed-loop control

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Figure 8-85 Slip compensation

8.24.1.3 V/f resonance damping

Data

Parameter range: P1338

Warnings: -
Faults: -
Function chart number: -

Description
Resonance effects result in an increased noise level and also can damage or destroy the
mechanical system. These resonance effects can occur for:
● Geared motors
● Reluctance motors
● Large motors
(low stator resistance → poor electrical damping)
The V/f resonance damping function is working between 6 % and 80 % of the rated motor
frequency when enabled.
Contrary to the "skip frequency" function and parameters P1091 … P1094, where the
resonance frequency is passed through as quickly as possible, for the V/f resonance
damping (P1338), the resonance effects are dampened from a control-related perspective.
The advantage of this function is that by using this active damping, operation is possible in
the resonance range.
The V/f resonance damping is activated and adjusted using parameter P1338. This
parameter represents a gain factor that is a measure for the damping of the resonance
frequency. The following oscillogram indicates the effect of the resonance damping function
using as an example a reluctance motor with gearbox. The phase output currents are
displayed for an output frequency of 45 Hz.

Control Units CU240S

8-166 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.24 Open-loop and closed-loop control

:LWKRXW9IUHVRQDQFHGDPSLQJ3  9IUHVRQDQFHGDPSLQJDFWLYH3 

Figure 8-86 Resonance damping

8.24.1.4 V/f control with FCC

Data

Parameter range: P1300, P1333

Warnings: -
Faults: -
Function chart number: -

Description
The inverters have a current measurement function. This permits the output current to be
precisely determined referred to the motor voltage. This measurement guarantees that the
output current is sub-divided into a load component and a flux component. Using this sub-
division, the motor flux can be controlled and can be appropriately adapted and optimized in-
line with the prevailing conditions.
FCC operation is only activated after the FCC starting frequency P1333 has been exceeded.
The FCC starting frequency P1333 is entered as a percentage to the rated motor frequency
P0310. For a rated motor frequency of 50 Hz and a factory setting of P1333 = 10 %, this
results in an FCC starting frequency of 5 Hz. The FCC starting frequency may not be
selected too low as this has a negative impact on the control characteristics and can result in
oscillation and system instability.
The "V/f with FCC" control type (P1300 = 1) has proven itself in many applications. It has the
following advantages with respect to the standard V/f control:
● Higher motor efficiency
● Improved stabilizing characteristics
– higher dynamic response
– improved behavior to disturbances/control.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-167
Functions
8.24 Open-loop and closed-loop control

Note
Contrary to closed-loop vector control, for the V/f open-loop control mode with FCC, it
is not possible to specifically influence the motor torque. This is the reason that it isn’t
always possible to avoid the motor stalling – even when using "V/f with FCC".
An improvement in the stabilizing behavior and in the motor efficiency can be
expected when using the closed-loop vector control when compared to V/f control with
FCC.

8.24.1.5 Current limiting (Imax controller)

Data

Parameter range: P1340 … P1346

r0056 bit 13
Warnings: A0501
Faults: F0001
Function chart number: FP6100

Description
In the V/f characteristic mode, the inverter has a current limiting controller in order to avoid
overload conditions (Imax controller, see figure below). This controller protects the inverter
and the motor against continuous overload by automatically reducing the inverter output
frequency by fImax (r1343) or the inverter output voltage by VImax (r1344). By either reducing
the frequency or voltage, the stressing on the inverter is reduced and it is protected against
continuous overload and damage.

Control Units CU240S

8-168 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.24 Open-loop and closed-loop control

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Figure 8-87 Imax controller

Note
The inverter load is only reduced when the frequency is reduced if the load decreases at
lower speeds (e.g. square-law torque –speed characteristic of the motor load).

8.24.2 Vector control

Description
Field-orientated Vector control (known as: Vector control) significantly improves torque
control when compared to V/f control. The Vector control principle is based on the fact that
for a specific load situation or required torque, the required motor current is impressed with
respect to the motor flux so that the appropriate torque is obtained. If the stator current is
emulated in a circulating coordinate system, linked with the rotor flux Φ, then it can be
broken-down into the flux-generating current component id in-line with the rotor flux and into
a torque-generating current component iq, vertical to the rotor flux. These components are
corrected to track their setpoints in the current controller using their own dedicated PI
controllers and are equal quantities in steady-state operation.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-169
Functions
8.24 Open-loop and closed-loop control

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Figure 8-88 Current vector diagram in a steady-state condition

Control Units CU240S

8-170 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.24 Open-loop and closed-loop control

In the steady-state condition, the field-generating current component id is proportional to the

flux Φ and the torque is proportional to the product of id and iq.
M ~ Φ * iq
Φ ~ id,stat
M ~ id * iq
When compared to V/f control, Vector control has the following advantages:
● Stable during load and setpoint changes
● Short rise times for setpoint changes (→ better control performance)
● Short rise times for load changes (→ better noise/disturbance characteristics)
● Accelerating and braking are possible with a max. adjustable torque
● The motor and motor machine are protected using the adjustable torque limit, both when
motoring and regenerating
● The motor and braking torque are controlled independently of the speed
● Full holding torque is possible at 0 speed.
These advantages are, under certain circumstances, already achieved without using speed
feedback.
The Vector control can be used both with and without speed encoder.
The following criteria provide a basis as to when a speed actual value encoder is required:
● High speed accuracy is required
● High requirements are placed on the dynamic response
– Improved control performance
– Improved immunity to disturbances.
● The torque is to be controlled over a control range greater than 1:10
● A defined and/or a changing torque has to be maintained for speeds below approx. 10 %
of the rated motor frequency P0310.
When it comes to entering a setpoint, the Vector control (see table below) is sub-divided into:
● Closed-loop speed control, and
● Closed-loop torque/current control (known as: Closed-loop torque control).

Table 8-35 Vector control versions

Vector control (closed-loop) Without encoder With encoder

Closed-loop speed control P1300 = 20 and P1501 = 0 P1300 = 21 and P1501 = 0
Closed-loop torque control P1300 = 22 or P1300 = 23 or
P1300 = 20 and P1501 = 1 P1300 = 21 and P1501 = 1
When closed-loop speed control is used, the closed-loop torque control is secondary. This
type of cascaded closed-loop control has proven itself in practice regarding commissioning
and increased transparency.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-171
Functions
8.24 Open-loop and closed-loop control

8.24.2.1 Vector control without speed encoder

Data

Parameter range: P1400 … P1780

P1610, P1611
P1750
P1755, P1756, P1758
Warnings: -
Faults: -
Function chart number: FP7000

Description
When Vector control is used without a speed encoder (SLVC) then the position of the flux
and the actual speed must be determined using the motor model. In this case, the model is
supported by the accessible currents and voltages. At low frequencies (≈ 0 Hz), the model is
not able to determine the speed. Inability of the model to determine the speed at ≈ 0 Hz,
uncertainty in model parameters and measurement inaccuracy are the reasons why there is
a changeover from closed-loop to open-loop controlled operation in this range.
The changeover between closed-loop controlled and open-loop controlled operation is
controlled using the time and frequency conditions (P1755, P1756, P1758) (see figure
below). The system does not wait for the time condition if the setpoint frequency at the ramp-
function generator input and the actual frequency simultaneously lie below P1756.

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Figure 8-89 Changeover condition for SLVC

In the open-loop controlled mode, the speed actual value is the same as the setpoint. For
suspended loads or when accelerating, parameter P1610 (constant torque boost) and P1611
(torque boost when accelerating) must be modified in order to allow the motor to provide the
steady-state and/or dynamic load torque. If P1610 is set to 0 %, then only the magnetizing
current r0331 is impressed for a value of 100 % of the rated motor current P0305. In order

Control Units CU240S

8-172 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.24 Open-loop and closed-loop control

that the motor does not stall when accelerating, P1611 can be increased or the acceleration
pre-control can be used for the speed controller. This is also practical in order that the motor
is not thermally overloaded at low speeds.
For Vector control without speed actual value encoder the SINAMICS G120 has, in the low
frequency range, the following outstanding features with respect to other AC inverters:
● Closed-loop controlled operation down to ≈ 1 Hz
● Can start in the closed-loop controlled mode (immediately after the motor has been
energized)
● The low frequency range (0 Hz) is passed-through in closed-loop controlled operation.

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Figure 8-90 Starting and passing through 0 Hz in closed-loop control

The following advantages are obtained as a result of closed-loop controlled operation down
to approx. 1 Hz (this can be selected using parameter P1755) as well as the possibility to
immediately start closed-loop controlled at 0 Hz or to reverse closed-loop controlled (this can
be set using parameter P1750):
● No changeover operation is required within the closed-loop control (smooth behavior –no
frequency dips)
● Continuous closed-loop speed-torque control is possible down to approx. 1 Hz.

Note
For closed-loop controlled reversing or closed-loop controlled starting from 0 Hz it must
be taken into account that when staying too long (> 2 s or > P1758) in the range around
0 Hz, that the closed-loop control automatically changes over from closed-loop into the
open-loop controlled mode.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-173
Functions
8.24 Open-loop and closed-loop control

8.24.2.2 Vector control with speed encoder

Data

Parameter range: P1400 … P1740

P0400 … P0494
Warnings: -
Faults: -
Function chart number: FP7000

Description
For Vector control with speed encoder (VC), a pulse encoder, e.g. an encoder with 1024
pulses per revolution is required. In addition to the correct wiring, the pulse encoder must be
activated, corresponding to the encoder type, using the parameter range P0400 … P0494.

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Figure 8-91 P0400 settings for a pulse encoder

Advantages of Vector control with encoder:

● The speed can be closed-loop controlled down to 0 Hz (i.e. at standstill)
● Stable control behavior over the complete speed range
● Constant torque in the rated speed range
● When compared to closed-loop speed control without encoder, the dynamic response for
motors with encoder is significantly higher as the speed is directly measured and is
incorporated in generating the model of current components id, iq.

Control Units CU240S

8-174 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.24 Open-loop and closed-loop control

8.24.2.3 Speed controller

Data

Parameter range: P1300, P1400 … P1780

SLVC: P1470, P1472, P1452
VC: P1460, P1462, P1442
Warnings: -
Faults: -
Function chart number: FP7500, FP7510

Description
Both of the control techniques (SLVC and VC) have the same speed controller structure
which includes the following components:
● PI controller
● Speed controller pre-control
● Droop
The sum of the output quantities forms the speed setpoint, which is reduced to the
permissible level using the torque setpoint limiting function.

Speed controller (SLVC: P1470, P1472, P1452 VC: P1460, P1462, P1442)
The speed controller (see figure below) receives its setpoint r0062 from the setpoint channel,
the actual value r0063 either directly from the speed actual value encoder for VC or through
the motor model for SLVC. The system error is amplified by the PI controller and, together
with the pre-control, forms the torque setpoint.
For increasing load torques, when the droop function is active, the speed setpoint is
proportionally reduced so that the load on an individual motor within a group (where two or
several motors are mechanically coupled) is reduced when excessively high torques occur.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-175
Functions
8.24 Open-loop and closed-loop control

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Figure 8-92 Speed controller

If the moment of inertia was entered, the speed controller (Kp,Tn) can be calculated using the
automatic parameterization (P0340 = 4). The controller parameters are defined according to
the symmetrical optimum as follows:
Tn = 4 * T σ
Kp = ｽ * r0345 / Tσ = 2 * r0345 / Tn
Tσ = sum of the low delay times
If oscillations occur with these particular settings, then the speed controller gain Kp should be
manually reduced. It is also possible to increase the speed actual value smoothing (this is
the usual procedure for gearbox play or high-frequency torsional oscillations) and then re-call
the controller calculation as the value is incorporated in the computation of Kp and Tn.
The following interrelationships apply for the optimization routine:
● If Kp is increased then the controller becomes faster and the overshoot is reduced.
However, the signal ripple and oscillations in the speed controller loop are increased.
● If Tn is reduced, then the controller also becomes faster. However, the overshoot
increases.
When manually adjusting the speed control, the simplest procedure is to initially define the
possible dynamic response using Kp (and the speed actual value smoothing) in order to then
reduce the integral action time as far as possible. In this case it is important to ensure that
the closed-loop control must also remain stable in the field-weakening range.
When oscillations occur in the closed-loop speed control, it is generally sufficient to increase
the smoothing time in P1452 for SLVC or P1442 for VC (or to reduce the controller gain) in
order to dampen oscillations.
The integral output of the speed controller can be monitored using r1482 and the unlimited
controller output can be monitored using r1508 (torque setpoint).

Control Units CU240S

8-176 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.24 Open-loop and closed-loop control

Note
When compared to closed-loop control with encoder, the dynamic response for sensorless
motors is significantly reduced. This is because the speed can only be derived from the
inverter output quantities for current and voltage which have the appropriate noise level.

Speed controller pre-control (P1496, P0341, P0342)

The control behavior of the speed control loop can be improved if the speed controller of the
inverter also generates values for the current setpoints (corresponds to the torque setpoint)
from the speed setpoint. The torque setpoint mv, is calculated as follows:
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This is entered into the current controller through an adaptation element directly as an
additive control quantity (this is enabled using P1496).
The motor moment of inertia P0341 is directly calculated during the quick commissioning or
the complete parameterization (P0340 = 1). The factor P0342 between the total moment of
inertia and motor moment of inertia must be manually determined.

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Figure 8-93 Speed controller with pre-control

When correctly adapted, the speed controller only has to correct noise
quantities/disturbances in its control loop and this is achieved with a relatively low
manipulated quantity change. On the other hand, speed setpoint changes bypass the speed
controller and are therefore executed faster.
The effect of the pre-control quantity can be adapted, depending on the particular
application, using the pre-control factor P1496. Using P1496 = 100 %, the pre-control is
calculated according to the motor and load moment of inertia (P0341, P0342). In order that
the speed controller does not work against the torque setpoint which is entered, a balancing
filter is automatically used. The time constant of the balancing filter corresponds to the

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-177
Functions
8.24 Open-loop and closed-loop control

equivalent delay time of the speed control loop. The speed controller pre-control is correctly
set (P1496 = 100 %, calibrated using P0342), if the I component of the speed controller
(r1482) does not change during a ramp-up or ramp-down in the range n > 20 % * P0310.
This means, using the pre-control, it is possible to approach a new speed setpoint without
overshoot (prerequisite: The torque limiting does not intervene and the moment of inertia
remains constant).
If the speed controller is pre-controlled, then the speed setpoint (r0062) is delayed with the
same smoothing (P1442 or P1452) as the actual value (r1445). This ensures that when
accelerating, there is no setpoint – actual value difference (r0064) at the controller input
which would have been exclusively caused by the signal propagation time.
When the speed pre-control is activated, it must be ensured that the speed setpoint is
continuously entered and without any significant noise level (avoid torque surges). An
appropriate signal can be generated by smoothing the analog signal P0753 or by activating
the rounding-off function of the ramp-function generator P1130 to P1133.

Note
The ramp-up and ramp-down times (P1120, P1121) of the ramp-function generator in the
setpoint channel should only be set so fast that when accelerating and braking, the motor
speed can follow the setpoint. This then guarantees the optimum functioning of the speed
controller pre-control.
The starting time r0345 is a measure for the overall moment of inertia of the machine and
describes that time in which the unloaded motor can accelerate from standstill to the rated
motor speed P0311 with the rated motor torque r0333.
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If these secondary conditions match the particular application, then the starting time can be
used as the shortest value for the ramp-up and ramp-down times.

Control Units CU240S

8-178 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.24 Open-loop and closed-loop control

Droop (P1488 … P1492)

The droop (enabled using P1488) means that with increasing load torque, the speed setpoint
is proportionally reduced.

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Figure 8-94 Speed controller with droop

Droop is the simplest method to implement load sharing control. However, this load sharing
control can only be used if the motors are operated more or less under steady-state
conditions (i.e. at constant speed). For motors, which are frequently accelerated and braked
with high speed changes, this technique is only conditionally suitable.
The most simple load sharing control is, e.g., used for applications where two or several
motors are mechanically coupled or operate on a common shaft and which have to fulfill the
requirements above. In this case, the droop controls torsional stressing associated with the
mechanical coupling by changing the speeds of the individual motors (excessive torques are
reduced for an individual motor).

Prerequisite
● All of the motors must be operated with closed-loop Vector speed control (with or without
speed actual value encoder)
● The ramp-up and ramp-down times of the ramp-function generator must be identical for
all of the motors.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-179
Functions
8.24 Open-loop and closed-loop control

8.24.2.4 Closed-loop torque control

Data

Parameter range: P1300, P1500 … P1511

P1400 … P1780
Warnings: -
Faults: -
Function chart number: FP7200, FP7210, FP7700, FP7710

Description
For sensorless closed-loop speed control SLVC (P1300 = 20) or for closed-loop speed
control with sensor VC (P1300 = 21), it is possible to changeover to closed-loop torque
control (slave motor) using BICO parameter P1501. It is not possible to changeover between
closed-loop speed and torque control if the closed-loop torque control is directly selected
using P1300 = 22 or 23. The torque setpoint and supplementary torque setpoint can be
selected using parameter P1500 and also using BICO parameter P1503 (CI: Torque
setpoint) or P1511 (CI: Supplementary torque setpoint). The supplementary torque acts both
for the closed-loop torque control as well as for the closed-loop speed control (see figure
below). As a result of this feature, a pre-control torque for the speed control can be
implemented using the supplementary torque setpoint.

Note
For safety reasons, it is presently not possible to assign fixed torque setpoints.

Control Units CU240S

8-180 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.24 Open-loop and closed-loop control

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Figure 8-95 Closed-loop speed and torque control

The sum of both torque setpoints is limited in the same way as the torque setpoint of the
speed control. Above the maximum speed (plus 3%), a speed limiting controller reduces the
torque limits in order to prevent the motor accelerating any further.
A "real" closed-loop torque control (with automatically set speed) is only possible in the
closed-loop controlled range but not in the open-loop controlled range. In the open-loop
controlled range, the torque setpoint changes the setpoint speed through a ramp-up
integrator (integration time ~ P1499 * P0341 * P0342). This is the reason that sensorless
closed-loop torque control in the area around standstill (0 speed) is only suitable for
applications which require an accelerating torque and not a load torque (e.g. traversing
motors). For closed-loop torque control with sensors, this restriction does not apply.
If the closed-loop torque control is active, and a fast stop command (OFF3) is output, then
the system automatically changes-over to closed-loop speed control and braking of the
motor is started. If a normal stop command (OFF1) is output, there is no changeover.
Instead, the system waits until a higher-level control has brought the motor to a standstill, in
order to inhibit the pulses. This is necessary in order to allow the master and slave motors to
be shut down together. For P1300 = 22 or 23, for OFF1, the motor is directly powered-down
(as for OFF2).

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-181
Functions
8.24 Open-loop and closed-loop control

8.24.2.5 Switch-over from Frequency to Torque Control

Data

Parameter range: P1300, P1501

Warnings: -
Faults: -
Function chart number: -

Description

Caution
Don't use SS1 or SLS in conjunction with Closed-loop torque control
Closed-loop torque control should not be used in conjunction with the failsafe functions SS1
and SLS, because the speed ramp functions, necesarry for SS1 and SLS are not available
together with the closed-loop torque control. So, if activating SS1 or SLS in case of Closed-
loop torque control, an LSTO will be generated immediately (after the time set in P9680 has
been passed) if the actual frequency exeeds the safety envelope.
The STO can be used with Closed-loop torque control without any restrictions.

The closed-loop torque control is switched-on via parameter P1501 during operation or
selected with parameter P1300 = 22, 23.

Table 8-36 Closed-loop torque control

Control mode P1501 = ON

Closed-loop P1300 = 20, 21 OFF1 command is not recognized.
speed control + fail-safe functions SLS, SS1 A safety fault is generated when the actual
frequency leaves the safety envelope.
Closed-loop P1300 = 22, 23 OFF1 command recognized as OFF2.
torque control + fail-safe functions SLS, SS1 A safety fault is generated when the actual
frequency leaves the safety envelope.

Control Units CU240S

8-182 Operating Instructions, 11/2006, A5E00766042B AA
 Functions
8.24 Open-loop and closed-loop control

8.24.2.6 Limiting the torque setpoint

Data

Parameter range: P1520 … P1531

P0640, r0067
r1407 bit 08, r1407 bit 09
Warnings: -
Faults: -
Function chart number: FP7700, FP7710 (CU240S)

Description
All of the following limits act on the torque setpoint which is either entered at the speed
controller output for closed-loop speed control or as torque input for closed-loop torque
control. The minimum is used from the various limits. This minimum is cyclically computed in
the inverter and displayed in parameters r1538, r1539.
● r1538 Upper torque limit
● r1539 Lower torque limit
This means that these cyclic values limit the torque setpoint at the speed controller
output/torque input and indicate the instantaneously maximum possible torque. If the torque
setpoint is limited in the inverter, then this is displayed using the following diagnostic
parameters
● r1407 bit 08 Upper torque limit active
● r1407 bit 09 Lower torque limit active

Torque limiting
The value specifies the maximum permissible torque whereby different limits are
parameterizable for motoring and regenerative operation.
● P1520 CO: Upper torque limit value
● P1521 CO: Lower torque limit value
● P1522 CI: Upper torque limit value
● P1523 CI: Lower torque limit value
● P1525 Scaling, lower torque limit value
The currently active torque limit values are displayed in the following parameters:
● r1526 CO: Upper torque limit value
● r1527 CO: Lower torque limit value

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 8-183
Functions
8.24 Open-loop and closed-loop control

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Figure 8-96 Torque limits

Power limits
This value specifies the maximum permissible power, whereby different limits can be
parameterized for motoring and regenerative operation.
● P1530 Motor power limit
● P1531 Regenerative power limit

Stall limiting
The stall limiting (locked rotor limiting) is internally calculated for the drive from the motor
data.

Current limiting
The current limiting additionally limits the maximum torque which the motor can provide. If
the torque limit is increased, more torque is only available if a higher current can flow. It may
be necessary to also adapt the current limit. The current limiting is influenced by:
● P0640
● Thermal motor protection
● Thermal inverter protection
After limiting, the instantaneous maximum possible inverter current is displayed in parameter
r0067 (limited output current).

Control Units CU240S

8-184 Operating Instructions, 11/2006, A5E00766042B AA
Technical data 9
9.1 CU240S Performance ratings

SINAMICS G120 Control Unit 240 (CU240)

Table 9-1 CU240 Performance ratings

Feature Specification
Operating voltage 24 V DC from Power Module or External 24 V DC (20.4 V … 28.8 V,
0.5 A) supply using the control terminals 31 and 32
Control method V/f control, output frequency between 0 Hz and 650 Hz:
(CU type dependent) Linear V/f control, Linear V/f control with FCC, Parabolic V/f control, Multi-
point V/f control, V/f control for textile applications, V/f control with FCC
for textile applications, V/f control with independent voltage setpoint,
Vector control, output frequency between 0 Hz and 200 Hz: Sensorless
Vector Control, Sensorless Vector Torque Control, Speed control with
Encoder feedback, Torque control with Encoder feedback.
PFH (only CU240S DP- PFH (probabillity of failures per hour) value = 1 * 10-7
F)
Fixed frequencies 16 programmable
Skip frequencies 4 programmable
Setpoint resolution 0.01 Hz digital; 0.01 Hz serial; 10 bit analog
(motor potentiometer 0.1 Hz [0.1 % in PID mode])
Digital inputs Up to 9 programmable digital inputs, isolated; PNP, SIMATIC-compatible,
(CU type dependent) low < 5 V, high > 10 V, maximum input voltage 30 V
Analog inputs Up to 2 programmable, both can be configured as additional digital inputs.
(CU type dependent) 0 V … 10 V, 0 mA … 20 mA and -10 V … +10 V (AI0)
0 V … 10 V and 0 mA … 20 mA (AI1)
Relay outputs 3 programmable, 30 V DC / 0 A …0.5 A (resistive)
Analog outputs 2 programmable
AO0: 0 V … 10 V & 0 mA … 20 mA, AO1: 0 mA … 20 mA
Dimensions (BxHxD) 73 mm x 178 mm x 55 mm
Weight 0.52 kg

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 9-1
Technical data
9.2 Technical data of PROFIBUS DP

9.2 Technical data of PROFIBUS DP

Technical data
To display information about the current operating state of the inverter and the
communication link, the PROFIBUS DP has three LEDs on the Standard Control Unit and
seven on the Control Unit with fail-safe functions.
Its voltage is supplied through the inverter system connector.
The PROFIBUS DP is connected to the PROFIBUS system using a 9-pin sub-D type socket
according to the PROFIBUS standard. All connections to this interface are short-circuit-proof
and isolated.
The PROFIBUS DP supports baud rates of 9.6 kbaud to 12 Mbaud.

Control Units CU240S

9-2 Operating Instructions, 11/2006, A5E00766042B AA
Spare parts/Accessories 10
10.1 Control Unit accessories

Operator Panel (OP)

The OP is a parameterization tool that is fitted directly to the SINAMICS G120 inverter via
the Option port. It can also be used for up and download of parameter sets. A detailed
description is given in the operation section.

PC Connection Kit
The PC Connection Kit is used to connect a PC (with STARTER software) to the inverter via
the Option port. It consists of a Null modem cable (3 m) and a PC inverter connector module.

Multi Media Card (MMC)

The Multi Media Card (MMC) is used to safe parameters from a Control Unit. Thus safed
parameter can be transferred to another Control Unit. A detailed description is given in the
operation section.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA 10-1
Spare parts/Accessories
10.1 Control Unit accessories

Screen Termination Kit

Figure 10-1 Screen Termination Kit

To prevent inductive and capacitive interference from effecting the correct function of the
system we recommend the screen termination kit. For correct installation refer to the
installation section.

Control Units CU240S

10-2 Operating Instructions, 11/2006, A5E00766042B AA
Appendix A
A.1 Electromagnetic Compatibility

Electromagnetic compatibility
All manufacturers/assemblers of electrical apparatus which "performs a complete intrinsic
function and is placed on the market as a single unit intended for the end user" must comply
with the EMC directive EC/89/336.
There are three routes for the manufacturer/assembler to demonstrate compliance:

Self-certification
This is a manufacturer's declaration that the European standards applicable to the electrical
environment for which the apparatus is intended have been met. Only standards that have
been officially published in the Official Journal of the European Community can be cited in
the manufacturer's declaration.

Technical construction file

A technical construction file can be prepared for the apparatus describing its EMC
characteristics. This file must be approved by a ‘Competent Body’ appointed by the
appropriate European government organization. This approach allows the use of standards
that are still in preparation.

EMC Standards
The SINAMICS G120 drives have been tested in accordance with the EMC Product
Standard EN 61800-3:2004.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA A-1
Appendix
A.2 Definition of the EMC Environment and Categories

A.2 Definition of the EMC Environment and Categories

Classification of EMC performance

The EMC environment and categories are defined within the EMC Product Standard
EN 61800-3, as follows:

First Environment
An environment that includes domestic premises and establishments that are connected
directly to a public low-voltage power supply network without the use of an intermediate
transformer.

Note
For example: houses, apartments, commercial premises or offices in a residential building.

Second Environment
An environment that includes industrial premises and establishments that are not connected
directly to a public low-voltage power supply network.

Note
For example: industrial and technical areas of buildings fed from a dedicated transformer.

● Category C1
Power Drive System (PDS) of rated voltage less than 1000 V intended for use in the First
(Domestic) Environment.
● Category C2
Power Drive System (PDS) of rated voltage less than 1000 V, which is neither a plug in
device nor a movable device, and when used in the First (Domestic) Environment, is only
intended to be installed and commissioned by a professional.

Note
A professional is a person or an organization having necessary skills in installing and/or
commissioning a Power Drive System (PDS), including their EMC aspects.

Control Units CU240S

A-2 Operating Instructions, 11/2006, A5E00766042B AA
 Appendix
A.2 Definition of the EMC Environment and Categories

● Category C3
Power Drive System (PDS) of rated voltage less than 1000 V intended for use in the
Second (Industrial) Environment and not intended for use within the First (Domestic)
Environment.

Table A-1 Compliance Table

Model Remarks
Category C1 - First Environment
-- The SINAMICS G120 drives are not intended for use within the Category
C1 Environment.
Category C2 - First Environment - Professional Use
Filtered Variants Drives FSB … FSF (400 V, 2.2 kW … 90 kW)
6SL3224-0BE**-*A*0 All units (except FSA) with integral filter.
Class A: 25 m screened cable type CY
The FSA power variant (400 V, 370 W … 1.5 kW) requires either a
footprint filter option (6SE6400-2FA00-6AD0) or additional power-line
filtering at the "system level".
When used in the First (Domestic) Environment this product may cause
radio interference in which case mitigation measures may be required.
Category C3 - Second Environment
Unfiltered Variants All units are available as unfiltered variants.
6SL3224-0BE**-*U*0 The use of unfiltered drives within an industrial installation is only possible
if it forms part of a system which includes additional power-line filtering at
the "system level" or, alternatively, the use of filtered variants.

Note
All drives should be installed and commissioned in accordance with the manufacturer’s
guidelines and in accordance with good EMC practices.
For further information refer to SIEMENS application note "EMC Design Guidelines".

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA A-3
Appendix
A.3 EMC Overall Performance

A.3 EMC Overall Performance

EMC Emissions
The SINAMICS G120 drives have been tested in accordance with the emission requirements
of the category C2 (domestic) environment.

Table A-2 Conducted & Radiated Emissions

EMC Phenomenon Standard Level

Conducted Emissions EN 55011 Class A
Radiated Emissions EN 55011 Class A

Note
To achieve this performance the default switching frequency should not be exceeded.
In order to achieve conducted emissions to EN 55011 Class B there is a range of PM240
external filter options available.

Achieving radiated emissions to EN 55011 Class B is largely dependent on the drive being
correctly installed inside a metallic enclosure. The limits will not be met if the drive is not
enclosed or installed in accordance with good EMC practices.

Harmonic Currents
The harmonic current emissions from the SINAMICS G120 drives is as follows:

Table A-3 Harmonic Currents

Rating Typical Harmonic Current (% of rated input current)

5th 7th 11th 13th 17th 19th 23rd 25th
FSA … FSF 73 52 25 23 22 15 12 10
(400 V, 370 W … 90 kW)

Note
Units installed within the category C2 (domestic) environment require connection to the
public low-voltage power supply network. Please contact your local supply network provider.

Control Units CU240S

A-4 Operating Instructions, 11/2006, A5E00766042B AA
 Appendix
A.3 EMC Overall Performance

Units installed within the category C3 (industrial) environment do not require connection
approval.

EMC Immunity
The SINAMICS G120 drives have been tested in accordance with the immunity requirements
of category C3 (industrial) environment:

Table A-4 EMC Immunity

EMC Phenomenon Standard Level Performance

Criterion
Electrostatic Discharge (ESD) EN 61000-4-2 4 kV Contact discharge A
8 kV Air discharge
Radio-frequency EN 61000-4-3 80 MHz … 1000 MHz A
Electromagnetic Field 10 V/m
Amplitude modulated 80 % AM at 1 kHz
Fast Transient Bursts EN 61000-4-4 2 kV @ 5 kHz A
Surge Voltage EN 61000-4-5 1 kV differential (L-L) A
1.2/50 μs 2 kV common (L-E)
Conducted EN 61000-4-6 0.15 MHz … 80 MHz A
10 V/rms
Radio-frequency Common Mode 80 % AM at 1 kHz
Mains Interruptions & Voltage EN 61000-4-11 100 % dip for 3 ms A
Dips 30 % dip for 10 ms B
60 % dip for 100 ms C
95 % dip for 5000 ms D
Voltage Distortion EN 61000-2-4 10 % THD A
Class 3
Voltage Unbalance EN 61000-2-4 3 % Negative Phase A
Class 3 Sequence
Frequency Variation EN 61000-2-4 Nominal 50 Hz or 60 Hz A
Class 3 (± 4 %)
Commutation Notches EN 60146-1-1 Depth = 40 % A
Class B Area = 250 % x degrees

Note
The immunity requirements apply equally to both filtered and unfiltered units.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA A-5
Appendix
A.4 Standards

A.4 Standards

European Low Voltage Directive

The SINAMICS G120 product range complies with the requirements of the Low Voltage Directive
73/23/EEC as amended by Directive 98/68/EEC. The units are certified for complaince with the following
standards:
EN 61800-5-1 — Semiconductor inverters –General requirements and line commutated inverters
EN 60204-1 — Safety of machinery –Electrical equipment of machines

European Machinery Directive

The SINAMICS G120 inverter series does not fall under the scope of the Machinery Directive. However,
the products have been fully evaluated for compliance with the essential Health & Safety requirements of
the directive when used in a typical machine application. A Declaration of Incorporation is available on
request.

European EMC Directive

When installed according to the recommendations described in this manual, the SINAMICS G120 fulfils
all requirements of the EMC Directive as defined by the EMC Product Standard for Power Drive Systems
EN 61800-3

Underwriters Laboratories
UL and CUL LISTED POWER CONVERSION EQUIPMENT for use in a pollution degree 2 environment.
Note: UL certification is presently in progress.

ISO 9001
Siemens plc operates a quality management system, which complies with the requirements of ISO 9001.

Control Units CU240S

A-6 Operating Instructions, 11/2006, A5E00766042B AA
 Appendix
A.5 Acceptance Log

A.5 Acceptance Log

A.5.1 Documentation of acceptance test

Overview

Acceptance test No.

Date
Person carrying-out

Table A-5 Machine description and overview/block diagram

Designation
Type
Serial No.
Manufacturer
End customer
Block/overview diagram of the machine

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA A-7
Appendix
A.5 Acceptance Log

Table A-6 Fail-safe functions for each drive

Drive No. FW version SI version Fail-safe function

r0018 = r9770 =
r0018 = r9770 =
r0018 = r9770 =
r0018 = r9770 =
r0018 = r9770 =
r0018 = r9770 =
r0018 = r9770 =
r0018 = r9770 =
r0018 = r9770 =
r0018 = r9770 =
r0018 = r9770 =
r0018 = r9770 =
r0018 = r9770 =
r0018 = r9770 =
r0018 = r9770 =
r0018 = r9770 =
r0018 = r9770 =
r0018 = r9770 =
r0018 = r9770 =
r0018 = r9770 =
r0018 = r9770 =
r0018 = r9770 =
r0018 = r9770 =
r0018 = r9770 =
r0018 = r9770 =
r0018 = r9770 =
r0018 = r9770 =
r0018 = r9770 =
r0018 = r9770 =
r0018 = r9770 =
r0018 = r9770 =
r0018 = r9770 =
r0018 = r9770 =

Control Units CU240S

A-8 Operating Instructions, 11/2006, A5E00766042B AA
 Appendix
A.5 Acceptance Log

Table A-7 Description of the fail-safe equipment/devices

Drive No. Example:

Wiring of the STO terminals (protective door, EMERGENCY STOP), grouping
of the STO terminals, etc.

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA A-9
Appendix
A.5 Acceptance Log

A.5.2 Function test of the acceptance test

Description
The function test must be carried-out separately for each individual drive
(assuming that the machine permits this to be done).

Executing the test

First commissioning Please mark

Series commissioning

Control Units CU240S

A-10 Operating Instructions, 11/2006, A5E00766042B AA
 Appendix
A.5 Acceptance Log

Function test "Safe Torque Off" (STO)

This test comprises the following steps:

Table A-8 "Safe Torque Off" function (STO)

No. Description Status

1. Initial state
• Drive in the "ready" state (P0010 = 0)
• No safety faults and alarms
• r9772.0 = r9772.1 = 0 (STO de-selected and inactive)
• P9659 = time intervals for the forced checking procedure correctly set
2. Operate the drive
3. Check that the expected drive operates
4. Select STO while issuing the command to operate
5. Check the following:
• The drive coasts-down
• The drive is braked by the mechanical brake and held if a brake is being
used
• No safety faults
• r9772.0 = r9772.1 = 1 (STO selected and active), r9772.14 = 1 if Safe
Brake Control is enabled
6. De-select STO
7. Check the following:
• No safety faults
• r9772.0 = r9772.1 = 0 (STO de-selected and inactive) , r9772.14 = 0
8. Check that the expected drive operates if so the following is tested:
• That the wiring between the control unit and power module is correct
• Correct assignment, drive No. – inverter power module – motor
• That the hardware is correctly functioning
• That the shutdown paths have been correctly wired
• Correct assignment of the STO terminals on the control unit
• Correct parameterization of the STO function
• Routine for the forced checking procedure of the shutdown paths

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA A-11
Appendix
A.5 Acceptance Log

Function test "Safe Stop 1" (SS1)

This test comprises the following steps:

Table A-9 "Safe Stop 1" function (SS1)

No. Description Status

1. Initial state
• Drive in the "ready" state (P0010 = 0)
• No safety faults and alarms
• r9772.0 = r9772.1 = 0 (STO de-selected and inactive)
• r9772.2 = r9772.3 = 0 (SS1 de-selected and inactive)
2. Operate the drive
3. Check that the expected drive operates
4. Select SS1 while issuing the traversing command
5. Check the following:
• Drive speed decreases corresponding to the selected ramp time (if
required, use a stop watch)
• After the parameterized minimum speed has been fallen below, the drive
coasts-down
• The drive is braked and held by the mechanical brake if a brake is being
used
• No safety faults
• r9772.1 = 1 (STO active)
• r9772.2 = 1 (SS1 selected)
• r9772.14 = 1 if safe brake monitoring is enabled
6. De-select SS1
7. Check the following:
• No safety faults
• r9772.1 = 0 (STO inactive)
• r9772.2 = 0 (SS1 de-selected)
• r9772.14 = 0
8. Check that the expected drive operates if so the following is tested:
• The wiring between the control unit and power module is correct
• Correct assignment, drive No. – inverter power module – motor
• Correct functioning of the hardware
• Correct wiring of the shutdown paths
• Correct assignment, STO terminals on the control unit
• Correct parameterization of the SS1 function

Control Units CU240S

A-12 Operating Instructions, 11/2006, A5E00766042B AA
 Appendix
A.5 Acceptance Log

Function test "Safely-Limited Speed" (SLS)

This test comprises the following steps:

Table A-10 "Safely-Limited Speed" function (SLS)

No. Description Status

1. Initial state
• Drive in the "ready" state (P0010 = 0)
• No safety faults and alarms
• r9772.4 = r9772.5 = 0 (SLS de-selected and inactive)
2. Operate the drive (if the machine permits it, at a higher speed than the
parameterized safely-limited speed)
3. Check that the expected drive operates
4. Select SLS while issuing the traversing command
5. Check the following:
• r9772.4 = 1 (SLS selected)
• Drive speed decreases corresponding to the selected ramp time or SLS
mode (if required, use an oscilloscope)
• After the parameterized safely-limited speed has been fallen below, the
speed remains below this limit
– In SLS mode 1 à correct, must be no fault
– In SLS mode 0 à LSTO (safety fault at ramping end)
– In SLS mode 2 à LSTO (immediately)
• r9772.5 = 1 (SLS active)
6. De-select SLS
7. Check the following:
• No safety faults
• r9772.4 = r9772.5 = 0 (SLS de-selected and inactive)
8. Check that the expected drive operates if so the following is tested:
• The wiring between the control unit and power module is correct
• Correct assignment, drive No. – inverter power module – motor
• Correct functioning of the hardware
• Correct wiring of the shutdown paths
• Correct parameterization of the SLS function

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA A-13
Appendix
A.5 Acceptance Log

A.5.3 Completing the acceptance log

Parameters of the fail-safe functions

Specified value checked?

Yes No
Control unit

Checksums

Drive Checksums
Name Drive No. Control unit (r9798) Control unit (r9898)

Control Units CU240S

A-14 Operating Instructions, 11/2006, A5E00766042B AA
 Appendix
A.5 Acceptance Log

Data back-up/archiving

Memory medium Saved where

Type Designation Date
Parameters
PLC program
Circuit diagrams

Signatures
Commissioning engineer
Confirms that the above listed tests and checks have been correctly carried-out.

Date Name Company/department Signature

Machinery construction OEM

Confirms the correctness of the parameterization documented above.

Date Name Company/department Signature

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA A-15
List of abbreviations B
B.1 Abbreviations

Abbreviations used with the SINAMICS G120 Products

Table B-1 Abbreviations used with the SINAMICS G120 Products

Abbreviations State
A
AC Alternating Current
A/D Analog digital converter
ADR Address
AFM Additional frequency modification
AG Automation Unit
AI Analog input
AK Request Identifier
AO Analog output
AOP Advanced operation panel
ASIC Application-specific integrated circuit
ASP Analog setpoint
ASVM Asymmetric space vector modulation
B
BCC Block check character
BCD Binary-coded decimal code
BI Binector input
BIA Berufsgenossenschaftliches Institut für Arbeitssicherheit
BICO Binector/connector
BO Binector output
C
C Commissioning
CB Communication board
CCW Counter-clockwise
CDS Command data set
CI Connector input
CM Configuration management
CMD Command

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA B-1
List of abbreviations
B.1 Abbreviations

Abbreviations State
CO Connector output
CO/BO Connector output/Binector output
COM Common (terminal is connected to NO or NC)
CT Commissioning, ready to run
CU Control Unit
CUT Commissioning, run, ready to run
CW Clockwise
D
D/A Digital analog converter
DC Direct current
DDS Drive data set
DI Digital input
DIP DIP switch
DO Digital output
DP Distributed I/Os
DP-V1 Acyclic data transfer (extended PROFIBUS function)
DS Drive state
E
ECD Equivalent circuit diagram
EEC European Economic Community
EEPROM Electrical erasable programmable read-only memory
ELCB Earth leakage circuit breaker
EMC Electromagnetic compatibility
EMF Electromagnetic force
ES Engineering System
FAQ Frequently asked question
F
FB Function block
FFB Freely Assignable Function block
FCC Flux current control
FCL Fast current limiting
FF Fixed frequency
FFB Free function block
FOC Field orientated control
FREQ Frequency
FSA Frame size A
FSB Frame size B
FSC Frame size C
FSD Frame size D
FSE Frame size E
FSF Frame size F
G

Control Units CU240S

B-2 Operating Instructions, 11/2006, A5E00766042B AA
 List of abbreviations
B.1 Abbreviations

Abbreviations State
GSD Device Data File (Geräte Stamm Datei)
GSG Getting Started Guide
GUI ID Global unique identifier
H
HIW Main actual value
HMI Human machine interface
HO High Overload (Constant Torque)
HSW Main setpoint
HTL High-voltage transistor logic
I
I/O In-/output
IBN Commissioning
IGBT Insulated gate bipolar transistor
IND Sub-index
J
JOG JOG
K
KIB Kinetic buffering
L
LCD Liquid crystal display
LED Light emitting diode
LGE Length
LO Light Overload (Variable Torque)
LWL Fiber Optic conductor
LSTO Latched Safe Torque Off
M
MHB Motor holding brake
MLP Multi-Language Pack
MOP Motor operated potentiometer
N
NC Normally closed
NEMA National Electrical Manufacturers Association
NO Normally open
O
OLM Optical Link Module
OLP Optical Link Plug
OM Object Manager
OP Operator Panel
OPI Operating Instructions
PA
PID Proportional, integral, derivative controller
PKE Parameter ID

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA B-3
List of abbreviations
B.1 Abbreviations

Abbreviations State
PKW Parameter ID value area (Parameterkennung Wert)
PLC Programmable logic control
PM Power module
PM-IF Power module interface
PNU Parameter Number
PNO PROFIBUS Nutzerorganisation
PPO Parameter process data object
PTC Positive temperature coefficient
PWE Parameter value
PWM Pulse-width modulation
Pxxxx Write parameter
PZD Process data area (Prozeßdaten)
Q
QC Quick commissioning
R
RAM Random-access memory
RCCB Residual current circuit breaker
RCD Residual current device
RFG Ramp-function generator
RFI Radio frequency interference
ROM Read-only memory
RPM Revolutions per minute
rxxxx read-only parameters of analogue signals
S
SBC Safe Break Control
SLVC Sensorless vector control
SLS Safe-Limited Speed
SOL Serial option link
SS1 Safe Stop 1
STO Safe Torque Off
STW Control word
STX Start of text
SVM Space vector modulation
T
TTL Transistor-transistor logic
U
USS Universal serial interface
V
V/f Voltage/frequency
VC Vector control
VT Variable torque
W

Control Units CU240S

B-4 Operating Instructions, 11/2006, A5E00766042B AA
 List of abbreviations
B.1 Abbreviations

Abbreviations State
WEA Automatic restart
Z
ZSW Status word
ZUSW Additional setpoint

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA B-5
Index
Compound braking, 8-86
Configuration with SIMATIC S7, 4-10
2 Control functions, 3-4
Control Wiring, 4-5
2-wire control, 8-41, 8-42
Control word, 5-87
Conversion of extended PROFIBUS DP
functionality, 5-93
3 Current limiting, 8-168, 8-184
3-wire control, 8-41

D
A Data sets, 8-6
Acceptance test, 5-75 DC braking, 8-82
Accessories DC link overvoltage, 8-138
Multi Media Card (MMC), 10-1 DC link undervoltage, 8-138
Operator Panel (OP), 10-1 Device-specific telegrams, 5-83
PC Connection Kit, 10-1 Digital inputs, 8-13
Screen Termination Kit, 10-2 Fixed frequencies, 8-37
Alarm messages, 7-3 Digital outputs, 8-16
Analog inputs, 8-18 Download parameters, 5-47, 5-48
Analog outputs, 8-20 Droop, 8-179
Dynamic braking, 8-88

B
E
BICO parameterization, 8-15
BICO technology, 8-3 Electromagnetic compatibility, A-1
Binector Connector Technology, 8-3 Electronic brakes, 8-82
blackout, 8-93 EMC precautions, 4-15
brownout, 8-93 EMC Standards, A-1
Bus terminator, 4-14 European EMC Directive, A-6
European Low Voltage Directive, A-6
European Machinery Directive, A-6
C Extended configuration for the SINAMICS G120, 5-82
Extended PROFIBUS DP functionality, 5-92
Calculating the motor/control data, 5-29
Changing parameters with the Operator Panel, 5-14
Chip temperature, 8-158
Classification of EMC performance, A-2
F
Closed-loop control, 8-160 Factory setting, 5-10
Closed-loop torque control, 8-180 Reset to, 5-60
Closed-loop Vdc control, 8-138 Fault messages, 7-3
Commissioning, 5-108 Fitting the Control Unit to the Power Module, 4-2
Commissioning functions, 3-3 Fixed frequencies, 8-37
Commissioning the application, 5-31 Flying restart, 8-96
Common features, 3-3 Flying restart with speed encoder, 8-98

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA Index-1
Index

Flying restart without speed encoder, 8-97 Motor data identification, 5-26
Forced dynamisation, 8-102 Motor holding brake, 8-78
Free function blocks, 8-69 Motorized potentiometer, 8-48

G N
General I/O DIP switches, 3-13 Normal Status LEDs, 7-6

H O
Heatsink temperature, 8-158 OP, 5-46, 5-47, 5-53
Open-loop control, 8-160
Operating functions, 3-4
I Options for SINAMICS G120, 3-2
Overload responses, 8-150, 8-158
I/O DIP switch, 8-18
i2t monitoring, 8-158
Imax controller, 8-168
Inputs and outputs, 8-13
P
Installation of PROFIBUS DP, 4-11 Parameter
Installing a G120 GSD file, 5-99 upload, 6-2
ISO 9001, A-6 Parameters
Access level, 5-5
Active, 5-8
J Atrributes, 5-4
BICO, 5-5
JOG, 8-50
Change state, 5-6
Data sets, 5-9
Data types, 5-6
K Grouping, 5-8
Kinetic buffering, 8-141 Quick commissioning, 5-9
KTY84 temperature sensor, 8-156 Unit, 5-7
Value range, 5-9
PID controller, 8-52
L PID dancer roll control, 8-56
PID fixed setpoint, 8-54
Limiting the torque setpoint, 8-183
PID motorized potentiometer, 8-54
Line failure, 8-93
PKW mechanism for processing parameters, 8-28
Line undervoltage, 8-93
Positioning ramp down, 8-143
Load torque monitoring, 8-147
Power module protection, 8-157
Power Modules
Fitting the Control Unit to the, 4-2
M Process dynamisation, 8-102
Manufacturer-specific telegrams, 5-83 PROFIBUS DP
Maximum cable lengths, 4-12 Extended functionality, 5-92
MMC PROFIBUS DP
Manual download, 5-54 Setting the address, 5-77
Upload, 5-53, 6-7 Switch over behavior, 5-86
Modification - frequency setpoint, 8-59 PROFIBUS DP
Monitoring functions / messages, 8-145 Conversion of extended functionality, 5-93
Monitoring parameters, 5-3 PROFIBUS DP DIP switches, 3-14
Monitoring the fail-safe functions, 8-101 PROFIBUS DP Interface, 4-10

Control Units CU240S

Index-2 Operating Instructions, 11/2006, A5E00766042B AA
 Index

PROFIBUS DP parameters, 5-79 Status word, 5-87

PROFIdrive Profile Swapping a CU, 6-12
User data structure, 5-77, 5-82 Swapping the PM, 6-12
PROFIsafe Parameters, 5-100 Switch over behavior, 5-86
PROFIsafe telegram structure, 5-85
Properties of the DPV1 parameter channel, 5-93
Protective functions, 3-4 T
Technical construction file, A-1
Telegrams, 5-82
R Temperature sensor, 8-155
Ramp-function generator, 8-61 Terminal layout, 3-12
Reducing the output frequency, 8-158 Thermal monitoring functions, 8-158
Reducing the pulse frequency, 8-158 Thermal motor model, 8-152
Reset to the factory setting, 5-60 Thermal motor protection, 8-150
Rules regarding hot swap, 6-11 Time controlled forced dynamisation, 8-101
Torque limiting, 8-183
Troubleshooting
S with the OP, 7-13
TTL Encoder, 5-109
Safe Stop 1 function, 8-110
Safely-Limited Speed function, 8-114
SafeTorque Off function, 8-107
Safety notes
U
Commissioning, 2-3 Underwriters Laboratories, A-6
Dismantling and disposal, 2-5 Universal Serial Interface, 8-22
General Warnings, Cautions and Notices, 2-2 Upload parameter, 5-15, 6-2
Operation, 2-4 Upload parameters, 5-47
Repair, 2-4 Used telegram types, 5-83
Safety Instructions, 2-1 USS, 8-22
Transport and storage, 2-3
Selecting the command source, 8-1
Selecting the setpoint source, 8-1 V
Self certification, A-1
V/f control, 8-160
Setpoint channel, 8-59
Vdc_max controller, 8-139
Siemens standard Control, 8-42
Vector control, 8-169
SIMATIC S7
with speed encoder, 8-174
BICO connection, 5-83
without speed encoder, 8-172, 8-174
Installing a G120 GSD file, 5-99
VIK/NAMUR telegram structure, 5-84
Read parameters, 5-102
Voltage boost, 8-163
Slip compensation, 8-165
Speed controller, 8-175
speed encoder
Flying restart with, 8-98
Flying restart without, 8-97
Stall limiting, 8-184
Standard telegram structure, 5-83
Standard telegrams, 5-83
Standards, A-6
STARTER
Download, 5-49
Upload, 5-49
Status display, 7-4

Control Units CU240S

Operating Instructions, 11/2006, A5E00766042B AA Index-3
Siemens AG

Automation and Drives

Standard Drives
Postfach 32 69
91050 Erlangen
Deutschland

www.siemens.de/sinamics-g120
Preface

Approbation
see chapter A.1 General technical data

CE label
see chapter A.1 General technical data

DP/DP Coupler
iv A5E00244669-03
 Preface

Manual guide
This manual is organized by the following topics:
• Product overview and description of the DP/DP Coupler
• Installation, wiring and commissioning
• Operation and diagnostics
• Appendices
• Important terminology is explained in the glossary.
• The index will help you to quickly find text passages associated with specific
keywords.

Recycling and disposal

The DP/DP Coupler can be recycled due to its low–pollutant equipment. For
environment–friendly recycling or disposal of your old equipment, contact a
company certified for the disposal of electronic waste.

Additional support
If you have any questions on the use of the product described in this manual that
are not answered here, please contact your local Siemens partner or branch office.
http://www.siemens.com/automation/partner
GSD files are available to you the Internet:
NOTICE:
Changed Link! http://www.ad.siemens.de/csi_e/gsd
http://support.automation.siemens.com/WW/view/en/23641045/130000

Training center
We offer courses for newcomers to the field of automation engineering. Please
contact your regional training center or the central training center in
D-90327 Nuernberg.
Phone: +49 (911) 895-3200.
Internet: http://www.sitrain.com

DP/DP Coupler
A5E00244669-03 v
Preface

A&D Technical Support

Worldwide, available 24 hours a day:

Nuernberg

Johnson City
Beijing

Technical Support

Worldwide (Nuernberg)
Technical Support

24 hours a day, 365 days a year

Phone: +49 (180) 5050-222
Fax: +49 (180) 5050-223
E-Mail: adsupport@
siemens.com
GMT: +1:00
Europe / Africa (Nuernberg) United States (Johnson City) Asia / Australia (Beijing)
Authorization Technical Support and Technical Support and
Authorization Authorization
Local time: Mon.-Fri. Local time: Mon.-Fri. Local time: Mon.-Fri.
8:00 AM to 5:00 PM 8:00 AM to 500 PM 8:00 AM to 5:00 PM
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GMT: +1:00 GMT: –5:00 GMT: +8:00

The languages of the SIMATIC Hotlines and the authorization hotline are generally German and English.

DP/DP Coupler
vi A5E00244669-03
 Preface

Service & Support on the Internet

Our documentation is supplemented with an online knowledge base on the
Internet.
http://www.siemens.com/automation/service&support
Here you will find the following:
• The newsletter that keeps you up-to-date with the latest information regarding
your products.
• The right documents, using our Service & Support search engine.
• A forum for the exchange of information between users and specialists
worldwide.
• Your local representative for Automation & Drives in our partner database.
• Information on local services, repairs, spare parts. Still more information is
available to you under ”Services”.

DP/DP Coupler
A5E00244669-03 vii
Preface

DP/DP Coupler
viii A5E00244669-03
Contents

Preface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii
1 Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 Field of application and function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Compatibility to precursor modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 Installation principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Installing the P/DP Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
3 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1 Electrical isolation and grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1.1 General rules and regulations for operation . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.1.2 Operation on a grounded power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.2 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.3 Connecting the power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.4 Connecting PROFIBUS DP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
4 Configuring and commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1 What are my steps in configuring the DP/DP Coupler? . . . . . . . . . . . . . . . 4-2
4.2 Setting the DIL switch on the DP/DP Coupler . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.2.1 Setting the “PS” DIL switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.2.2 Setting the “DIA” DIL switch (data validity indication) . . . . . . . . . . . . . . . . . 4-4
4.2.3 Setting the “ADDR” DIL switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.2.4 Setting the PROFIBUS address on the DIL switch . . . . . . . . . . . . . . . . . . . 4-6
4.3 Configuring the DP/DP Coupler in STEP 7 . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.3.1 Configuring the DP/DP Coupler in STEP 7 . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.3.2 Setting the PROFIBUS address in STEP 7 . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.3.3 Setting the properties of the DP/DP Coupler in STEP 7 . . . . . . . . . . . . . . . 4-11
4.3.4 Example of a configuration of the DP/DP Coupler I/O in STEP 7 . . . . . . . 4-12
4.4 Configuring the DP/DP Coupler with another engineering tool . . . . . . . . . 4-13
4.5 Commissioning the DP/DP Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
5 Operation of the DP/DP Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1 Replacement of a faulty DP/DP Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 Response times of the DP/DP Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

DP/DP Coupler
A5E00244669-03 ix
Contents

6 Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1 Diagnostics by means of LED indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2 Diagnostics by means of the user program . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.2.1 Structure of the slave diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.2.2 Standard diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.2.3 Status message (module diagnostics) – only for operation on a
DP master (DPV1) or S7 DP master . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6.2.4 Module diagnostics - replacement part mode or operation on a
DP master (DPV0) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
6.3 Example of a diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
6.3.1 Task . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
6.3.2 Solution with STEP 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
A Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
A.1 General technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
A.1.1 Standards and approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
A.1.2 Electromagnetic compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6
A.1.3 Transportation and storage conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8
A.1.4 Mechanical and climatic ambient conditions for operation . . . . . . . . . . . . . A-9
A.1.5 Data on insulation tests, protection class and degree of protection . . . . . A-11
A.1.6 Rated voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-11
A.2 Technical data of the DP/DP Coupler (6ES7 158-0AD01-0XA0) . . . . . . . . A-12
A.3 Use of the DP/DP Coupler in potentially explosive environments
of Zone 2 (in all official EU languages) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-13
B Order numbers and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Glossary
Index

DP/DP Coupler
x A5E00244669-03
 Contents

Figures
1-1 DP/DP coupling of two PROFIBUS DP networks . . . . . . . . . . . . . . . . . . . . 1-1
1-2 Function principle of the DP/DP Coupler (example) . . . . . . . . . . . . . . . . . . 1-2
1-3 Operator and display elements of the DP/DP Coupler . . . . . . . . . . . . . . . . 1-3
2-1 Remove the slide on the bottom of the module before you install it on
the S7 system rail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
3-1 Termination of the PROFIBUS cable shielding on the grounded
shielding busbar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3-2 Configuration with a grounded supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3-3 Connections of the DP/DP Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3-4 Power supply für den DP/DP Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
4-1 Example of DIL switch settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4-2 Example: Configuration of the DP/DP Coupler on network 1 . . . . . . . . . . . 4-12
4-3 Example: Configuration of the DP/DP Coupler on network 2 . . . . . . . . . . . 4-13
6-1 Status / error displays of the DP/DP Coupler . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6-2 Structure of the standard diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6-3 Structure of module diagnostics (DPV1 / S7 DP master) . . . . . . . . . . . . . . 6-9
6-4 Structure of module diagnostics (replacement part mode or operation
on a DP master (DPV0)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
6-5 Example of the analysis of diagnostics data from the DP/DP Coupler . . . 6-11

Tables
4-1 How to configure the DP/DP Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4-2 Meaning of the ”DIA” switch positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
6-1 Meaning of the LEDs ON 1 and ON 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6-2 Status / error messages of the DP/DP Coupler . . . . . . . . . . . . . . . . . . . . . . 6-3
6-3 Length and start addresses of the diagnostics blocks for operation
on a DP master (DPV1) or S7 DP master . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6-4 Length and start addresses of the diagnostic blocks in
replacement mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6-5 Structure of station status 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6-6 Structure of station status 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6-7 Structure of station status 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6-8 Structure of the device identifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6-9 Call of the SFC 13 (DPNRM_DG) in the OB 1 . . . . . . . . . . . . . . . . . . . . . . 6-12
6-10 Example: Analysis of the diagnostics data . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
A-1 Use in industrial environments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
A-2 Pulse-type interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6
A-3 Sinusoidal interference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7
A-4 Transportation and storage conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8
A-5 Mechanical ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-9
A-6 Test for mechanical ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10
A-7 Climatic ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10
A-8 Test voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-11
B-1 Order numbers for the DP/DP Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

DP/DP Coupler
A5E00244669-03 xi
Contents

DP/DP Coupler
xii A5E00244669-03
Product Overview 1
1.1 Field of application and function

Field of application
DP/DP Coupler is used to interconnect two PROFIBUS DP networks in order to
enable the transfer of data between the master of both networks.
The maximum length of transferred data consists of 244 bytes of input data and
244 bytes of output data.

PG

S7-400
S7-300

DP/DP Coupler
ET 200X S7-300 ET 200L Drive
ET 200S

Figure 1-1 DP/DP coupling of two PROFIBUS DP networks

Configuration
You configure the DP/DP Coupler using either STEP 7 or a programming tool that
integrates the DP/DP Coupler by means of a GSD file.
In STEP 7, you can set up the required length of input and output data. The output
data on one side of the DP/DP Coupler form the input data of the other, and vice
versa.
In STEP 7, define the I/O data areas based on the slot IDs.

DP/DP Coupler
A5E00244669-03 1-1
Product Overview

Example
The example below shows the independence of both networks. That means, you
configure a separate PROFIBUS address for each PROFIBUS DP network.
In the figure below, that is PROFIBUS address 3 in network 1, and PROFIBUS
-address 50 in network 2.

DP/DP Coupler

Output area PROFI- Input area PROFI-

BUS DP BUS DP
Network 1 Network 2
PROFIBUS DP PROFIBUS DP
16 by- 16 by- Network 2
Network 1 tes tes

Input area PROFI- Output area PROFI-

1.5 Mbps BUS DP BUS DP 12 Mbps
Network 1 Network 2

8 bytes PROFIBUS
PROFIBUS 8 bytes 8 bytes address 50
address 3

Figure 1-2 Function principle of the DP/DP Coupler (example)

Both networks may operate at different baud rates. The rate at which network 1
writes data to the output buffer is slower than the rate at which network 2 reads
these data. Hence, network 2 reads the same data successively. The effect is the
reverse when data are transferred from network 2 to network 1. The output buffer
will be overwritten several times before network 1 reads the data buffer. This
means that only the currently written data are available.

Notice
You need to balance the I/O area of both networks.

DP/DP Coupler
1-2 A5E00244669-03
 Product Overview

Appearance
The figure below shows the DP/DP Coupler and its operator and display elements:

SIEMENS

Indicator LEDs SF1

DP1 DP2
SF2
64
BF1 32
DIL switch for network 1 (cf. 16
DIL switch for network 2 (cf.
chapter 4.2) BF2 chapter 4.2)
8
ON1 4
ON: PROFIBUS address 2
ON: PROFIBUS address by
by means of STEP 7 on ON2 means of STEP 7 on network
1
network 1 2
ADDR
ON: Data validity indication ON: Data validity indication
enabled for network 1 DIA enabled for network 2
PS
ON: DP/DP Coupler is con- ON ON ON: DP/DP Coupler is con-
nected to the power supply of X1 DP1 X2 DP2 nected to the power supply of
network 1 network 2

PROFIBUS DP connection PROFIBUS DP connection

for network 1 for network 2

Power supply connection for

network 1 L+
M
Power supply connection for
network 2 L+
M

Figure 1-3 Operator and display elements of the DP/DP Coupler

Features
Properties of the DP/DP Coupler:
• Maximum length of data exchanged consists of 244 bytes input data and 244
bytes of output data, of which up to 128 bytes are consistent
• Up to 16 I/O areas for data exchange
• If one side fails, the output values of the other are retained
• DPV1 is supported with full and uniform diagnostic functions
• PROFIBUS address setting either via selector switch on the DP/DP Coupler, or
in STEP 7, or by means of another programming tool
• Different transmission rates and PROFIBUS addresses on both sides of the
DP/DP Coupler
• Electrical isolation between the DP networks
• Dual power supply

DP/DP Coupler
A5E00244669-03 1-3
Product Overview

1.2 Compatibility to precursor modules

The DP/DP Coupler, order no. 6ES7 158-0AD01-0XA0, is compatible with the
DP/DP Coupler, order no. 6ES7 158-0AD00.0XA0. We have enhanced the
diagnostic information for SYNC and FREEZE mode on Link 6ES7
158-0AD01-0XA0 compared with DP/DP Coupler 6ES7 158-0AD00-0XA0, and
adapted these data in accordance with PROFIBUS standard.
The DP/DP Coupler 6ES7 158-0AD01-0XA0 can be used to replace previous
module versions. The design is compatible.
The DP/DP Coupler is available as spare part under order no.
6ES7 158-0AD00-0XA0.

DP/DP Coupler
1-4 A5E00244669-03
Installation 2
Overview of contents

Section Topic Page

2.1 Installation principles 2-1
2.2 Installing the DP/DP Coupler 2-2

2.1 Installation principles

Mounting position
The mounting position of the DP/DP Coupler is user–specific. Please note, that the
ambient temperature may not exceed 60
C when the device is mounted vertically,
and for all other mounting positions 40
C.
For further information on operational conditions, refer to chapter A.1.

Open equipment
The DP/DP Coupler is an open device. It may only be installed in cubicles,
cabinets or electrical control rooms which can only be accessed by means of a key
or a tool. Only trained or authorized personnel should have access to the housings,
cabinets or electrical control rooms.

Mounting system
The DP/DP Coupler may be mounted on a DIN rail (7.5 mm and 15 mm), or on an
S7 system profile rail . Ample free space of at least 40 mm above and below the
module should be provided for the installation.
For more information on installing S7 modules, refer to the S7-300 Programmable
Controller, Installation manual.

DP/DP Coupler
A5E00244669-03 2-1
Installation

2.2 Installing the DP/DP Coupler

Components required
• DP/DP Coupler
• Profile rail:
– DIN rail (7.5 mm or
– 15 mm), or
– a rail for the S7 mounting system
Component order nos. are found in appendix B.

Installing the DP/DP Coupler on a DIN rail

Step Activity
1 When you install the DIN rail, make sure you provide at least 40 mm of free
space above and below the modules in order to allow easy installation and the
deflection of heat.
Note: Always ensure a low–impedance connection between the DIN rail and
the grounded sheet metal plate or mounting panel. For the installation on
varnished or galvanized sheet metal you should use a suitable contact agent or
contact disks, for example.
2 Hang the DP/DP Coupler onto the DIN rail and then swing it down.
3 Screw–tighten the DP/DP Coupler.
4 Wire the DP/DP Coupler as described in chapter 3.

DP/DP Coupler
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 Installation

Installing the DP/DP Coupler on a profile rail for the S7 installation system

Step Activity
1 When you install the S7 profile rail, make sure you provide at least 40 mm of
free space above and below the modules in order to allow easy installation and
the deflection of heat.
Note: Always ensure a low–impedance connection between the DIN rail and
the grounded sheet metal plate or mounting panel. For the installation on
varnished or galvanized sheet metal you should use a suitable contact agent or
contact disks, for example.
2 Remove the slide from the bottom of your DP/DP Coupler with the help of a
screwdriver (see fig. 2-1).
3 Hang the DP/DP Coupler onto the S7 profile rail and then swing it down.
4 Screw–tighten the DP/DP Coupler.
5 Wire the modules as described in chapter 3.

Figure 2-1 Remove the slide on the bottom of the module before you install it on the S7
system rail

Removing the DP/DP Coupler

You remove the DP/DP Coupler in reverse order.
Switch off the 24 V DC power supply to the DP/DP Coupler before you remove it.

DP/DP Coupler
A5E00244669-03 2-3
Installation

DP/DP Coupler
2-4 A5E00244669-03
Wiring 3
Overview of contents
This chapter informs you of general requirements for wiring the DP/DP Coupler
and of the connections you need.

Section Topic Page

3.1 Electrical isolation and grounding 3-1
3.2 Connections 3-6
3.3 Connecting the power supply 3-7
3.4 Connecting PROFIBUS DP 3-8

3.1 Electrical isolation and grounding

Overview of contents

Section Topic Page

3.1.1 General rules and regulations for operation 3-2
3.1.2 Operation with a grounded supply 3-5

Dual 24 V DC power supply

You may connect the DP/DP Coupler to two separate 24 V DC power supply
modules.

Properties of the DP/DP Coupler

• both PROFIBUS DP networks are galvanically isolated
• both PROFIBUS DP networks are galvanically isolated from the 24 V DC power
supply
• both 24 V DC power supplies are galvanically isolated
• PROFIBUS DP (network 1) and the logic components of the DP/DP Coupler
are galvanically interconnected

DP/DP Coupler
A5E00244669-03 3-1
Wiring

Ungrounded power supply

Note
The DP/DP Coupler must be operated on a grounded 24 V DC power supply. It
can not be operated on an ungrounded 24 V DC power supply!

3.1.1 General rules and regulations for operation

Introduction
When the described modules are used in a system, certain rules and regulations
must be followed that depend on the area of application.
This section provides an overview of the most important rules that must be
observed for safe integration in a system.

Specific applications
Please comply with the safety and accident prevention regulations (e.g. machine
protection guidelines) that are valid for specific applications.

EMERGENCY–OFF equipment
EMERGENCY-OFF equipment to IEC 6204 (corresponds with DIN VDE 113) must
retain an operational state in all operating modes of then system or plant.

DP/DP Coupler
3-2 A5E00244669-03
 Wiring

Start-up of the system following specific events

The following table shows what you have to look out for when the system starts up
after certain events.

In the case of ... ...

The system starts up after a voltage dangerous operating states may not develop. If
dip or power failure necessary, force an ”EMERGENCY–OFF”!
Start-up of the system after
interruption of bus communication,
Startup after the an uncontrolled or undefined state must be
”EMERGENCY–OFF” system is prevented.
released
Startup of the system without the DP
master addressing the slaves,

24V DC power supply

The following table shows what you have to look out for in the case of the 24V
supply.

In the case of ... You must remember ...

Buildings External lightning protection Lightning protection
measures (e.g.
(
24 V DC power supply Internal lightning protection
lightning conductors)
cables, signal cables
24 V DC supply Safety extra-low voltage with safe electrical isolation (SELV)

Note
For information on lightning protection, refer to the S7–300 PLC; Installation
installation manual.

Protection from external electrical interference

The following table shows what you have to look out for to ensure protection
against electrical influences or faults.

In the case of ... You must ensure that ...

All systems in which the ... The system is connected to the protective conductor so
modules are integrated that electromagnetic interference can be discharged.
Connecting, signal and bus ... The cable has been routed and installed correctly.
lines
Signal and bus lines ... Cable or conductor breaks do not lead to undefined
system states.

DP/DP Coupler
A5E00244669-03 3-3
Wiring

Shielding braid of the PROFIBUS cable

The shielding braid of the PROFIBUS cable must be terminated on a grounded
shielding busbar.
• Connect the shielding braid with the help of metal cable clamps.
• Terminate the shielding to a shielding busbar which is mounted directly
downstream of the cable inlet of the cabinet.
• The clamp should provide good contact to a large area of the shielding.

Switch cabinet

Figure 3-1 Termination of the PROFIBUS cable shielding on the grounded shielding
busbar

DP/DP Coupler
3-4 A5E00244669-03
 Wiring

3.1.2 Operation on a grounded power supply

Definition: Grounded power supply

The neutral conductor of grounded supplies is bonded to earth. An earth fault
between a voltage-carrying conductor or grounded part of the system trips the
connected protective devices.

Components and protective measures

Various components and protective measures are prescribed for the system
installation. The type of components used and degree of protection for your system
configuration is specified in accordance with DIN VDE directives.
• Main switch (see Figure 3-2, ): DIN VDE 0100 Part 460
• Isolator (see Figure 3-2, ): DIN VDE 0113 Part 1

Operation on grounded power supply

Figure 3-2 shows the position of the modules in a configuration connected to a
TN-S power supply network. In installations with grounded reference potential,
interference currents are discharged via the protective conductor.
Note: The arrangement of the power connections shown does not correspond to
the actual arrangement on the modules; it was selected in the interest of clarity.

L1 Low-voltage distribution, e. g.
L2
L3 TN-S system (3 x 400 V)
N
PE
Cabinet


Rail DP/DP Coupler

L+
 AC
DC
M

Logic
L+
 AC
DC
M

Equipotential busbar in the switch cabinet

Figure 3-2 Configuration with a grounded supply

DP/DP Coupler
A5E00244669-03 3-5
Wiring

3.2 Connections

Connections of the DP/DP Coupler

The figure below shows all interconnections of the DP/DP Coupler:

PROFIBUS DP
network 2

24 V DC 24 V DC PROFIBUS DP
from from network 1
network 1 network 2

Figure 3-3 Connections of the DP/DP Coupler

DP/DP Coupler
3-6 A5E00244669-03
 Wiring

3.3 Connecting the power supply

Required tool
To connect the power supply, you require a 3 mm screwdriver.

Power supply unit

You may only use power supply modules of the type PELV with electrically isolated
operational extra–low voltage (v 60 V DC).

Dual power supply

You can use two separate power supply sources for the DP/DP Coupler:
• This power supply is redundant, i.e. in case of a module failure, the
DP/DP Coupler automatically switches over the other source module.
• If both connections are under load (network 1 / network 2), the DP/DP Coupler
automatically uses the network 1 power source.
• When using only a single power supply for the DP/DP Coupler, you should
preferably connect this to PS2.

Note
The diagnostic system shows you whether the DP/DP Coupler is connected to the
24 V DC power supply or not. Always set the “PS” switch on the DP/DP Coupler to
the correct position!
For further information on the DIL switch settings, refer to chapter 4.2.

Power supply connector

The 4-pin 24 V DC power supply connector is located on the front panel of the
DP/DP Coupler. The connections have the following functions:

L+ +24 V DC from network 1

M Chassis ground fro network 1
L+ +24 V DC from network 2
M Chassis ground from network 2

Figure 3-4 Power supply für den DP/DP Coupler

DP/DP Coupler
A5E00244669-03 3-7
Wiring

The maximum conductor cross-section is 2.5 mm2. A cable strain relief is not
provided.

Step Activity
1 Strip the wires to a length of 10 mm.

2 Connect the wires to the 2–pin screw terminals of the connector. This connector
is plugged into the power supply socket on the supplied unit.
When a dual power supply is available for the DP/DP Coupler, you should
connect both.
If you only have one, you should preferably connect it to PS2.
3 Plug the wired 2–pin connector into the power supply socket of your DP/DP
Coupler.
4 Set the “PS” selector switch on the DP/DP Coupler:
• L+/M (PS1) connected to 24 V DC: Selector switch PS (DP1) to “ON”
• L+/M (PS2) connected to 24 V DC: Selector switch PS (DP2) to “ON”
The selector switch “PS” must be set properly in order to allow the correct
evaluation of diagnostic data in STEP 7!

3.4 Connecting PROFIBUS DP

Required tool
You need a screwdriver with a blade width of 3 mm to install the bus connector to
the DP/DP Coupler.

Bus cable and connector

Always use the accessories specified in appendix B for PROFIBUS DP.
For information on handling bus cables and connectors, refer to the
Distributed I/O System ET 200 manual.

Procedure
To connect PROFIBUS DP:
1. Insert the bus connector into the PROFIBUS socket.
2. Tighten the mounting screws on the bus connector.

DP/DP Coupler
3-8 A5E00244669-03
Configuring and commissioning 4
Contents
This chapter shows you the steps in commissioning the DP/DP Coupler. Details
are found in the relevant subsections.

Section Topic Page

4.1 What are the steps in commissioning DP/DP Coupler? 4-2
4.2 Setting the DIL switch on the DP/DP Coupler 4-3
4.3 Programming the DP/DP Coupler in STEP 7 4-8
4.4 Programming the DP/DP Coupler using another engineering tool 4-13
4.5 Commissioning of the DP/DP Coupler 4-14

DP/DP Coupler
A5E00244669-03 4-1
Configuring and commissioning

4.1 What are my steps in configuring the DP/DP Coupler?

The table below shows you the steps required in commissioning.

Table 4-1 How to configure the DP/DP Coupler

Step Activity Content Further

information
1 Mounting You have mounted the DP/DP Coupler onto a profile Chapter 2
rail.
2 Wiring You have connected the DP/DP Coupler to the power Chapter 3
supply and to PROFIBUS DP.
3 Setting the “PS” Setting for both sides, according to the power supply Chapter 4.2.1
DIL switch connection to the DP/DP Coupler.
4 Setting the “DIA” Setting for both sides, defines whether to validate Chapter 4.2.2
DIL switch transferred input data.
5 Setting the “ADDR” Setting for both sides, to define whether the PROFIBUS Chapter 4.2.3
DIL switch address is set by means of DIL switch or in STEP 7.
6 Setting the Set the PROFIBUS address for both sides, using either
PROFIBUS the DIL switch or STEP 7.
address
dd
• by means of DIL switch Chapter 4.2.4
• in STEP 7 Chapter 4.3.2
7 Configuring the • using STEP 7 Chapter 4
4.3.1
31
DP/DP Coupler
• using another engineering tool Chapter 4.4
8 Commission the Switch on the DP/DP Coupler and load the Chapter 4.5
DP/DP Coupler configuration data

DP/DP Coupler
4-2 A5E00244669-03
 Configuring and commissioning

4.2 Setting the DIL switch on the DP/DP Coupler

Contents

Section Topic Page

4.2.1 Setting the “PS” DIL switch 4-3
4.2.2 Setting the “DIA” DIL switch (data validity indication) 4-4
4.2.3 Setting the “ADDR” DIL switch 4-5
4.2.4 Setting the PROFIBUS address on the DIL switch 4-6

4.2.1 Setting the “PS” DIL switch

Function of the “PS” (Power Supply) DIL switch

The “PS” DIL switch setting tells the DP/DP Coupler to which of its inlets the power
supply is connected. This also allows the diagnostic function to report failures of
the power supply.

Setting the “PS” DIL switch

Set the proper position of the “PS” DIL switch für sides of the DP/DP Coupler:
• PS (DP1) set to “ON”: L+/M (PS1) is connected to 24 V DC
• PS (DP2) set to “ON”: L+/M (PS2) is connected to 24 V DC

Note
The DP/DP Coupler accepts all changes immediately.

DP/DP Coupler
A5E00244669-03 4-3
Configuring and commissioning

4.2.2 Setting the “DIA” DIL switch (data validity indication)

Function of the “DIA” DIL switch (data validity indication)

The “DIA” DIL switch function allows you to validate I/O data.
The setting of the “DIA” DIL switch does not influence the normal diagnostic
messages of the DP/DP Coupler described in chapter 6.2.

Function principle of the data validity indication

The DP/DP Coupler enables the data transfer between two PROFIBUS DP
networks. If one of the DP masters is silent, or data exchange is not possible due
to an error at one of the DP/DP Coupler interfaces, the partner DP master should
recognize invalid data transferred via the DP/DP Coupler.
You can validate data either by means of the slave diagnostics functions, or
directly by analyzing the I/O data.

“DIA” in “OFF” position

I/O data validation is disabled when the “DIA” switch is set to “OFF”.

“DIA” in “ON” position

I/O data validation is enabled when the “DIA” switch is set to “ON”.

Table 4-2 Meaning of the ”DIA” switch positions

DIA switch position Validation of

DIA = ON (DP1) input data from network 1 = output data from network 2
DIA = ON (DP2) input data from network 2 = output data from network 1

The function uses the first bit of the LSB byte of the first configured input byte:
• Bit 1 (LSB inputs) = 1: Data from DP/DP Coupler are valid
• Bit 1 (LSB inputs) = 0: Data from DP/DP Coupler are invalid
Example
• Network 1: 8 byte input data – 16 byte output data
• Network 2: 16 byte input data – 8 byte output data
The first bit of the 8 byte of input data indicates validity of data from network 2, the
first bit of the 16 byte input data indicates validity of data from network 1.

DP/DP Coupler
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Warning
! When “DIA” is in “ON” position, you may not use the first bit in the LSB of the first
configured input byte for normal input data!
We advise you not to use the first byte of the input data for the inputs when using
the data validity indication function!

Note
The DP/DP Coupler accepts all changes immediately.

4.2.3 Setting the “ADDR” DIL switch

Function of the “ADDR” (PROFIBUS address) DIL switch

The position of this switch determines whether the PROFIBUS address is set
directly on the DP/DP Coupler, or whether it is assigned via PROFIBUS DP in the
STEP 7 program.

Setting “ADDR”
Set the relevant position of the “ADDR” DIL switch for both sides of the
DP/DP Coupler:
• “ADDR” in “OFF” position: The PROFIBUS address is set directly on the
DIL switch of the DP/DP Coupler.
For further information, refer to chapter 4.2.4.
• “ADDR” in “ON” position: The PROFIBUS address is assigned in the STEP 7
program.
For further information, refer to chapter 4.3.2.

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Configuring and commissioning

4.2.4 Setting the PROFIBUS address on the DIL switch

Definition
Each bus node must receive a PROFIBUS address so that it can be uniquely
identified on PROFIBUS-DP. The PROFIBUS address is set separately for both
PROFIBUS DP networks directly on the DIL switches of the DP/DP Coupler.
Note:
You can also assign the PROFIBUS address in STEP 7 (cf. chapter 4.3.2).

Rules
Rules for the assignment of a PROFIBUS address:
• Valid PROFIBUS address range: 1 to 125.
• All PROFIBUS addresses assigned must be unique within the DP master
system.
• You assign a PROFIBUS address to each side of the DP/DP Coupler. It is also
possible to assign the PROFIBUS address for one side of the DP/DP Coupler
directly on the Link, and the other in STEP 7.

Required tool
To set the PROFIBUS address, you require a 3 mm screwdriver.

How to set the PROFIBUS address directly on the DP/DP Coupler

Step Activity
1 Switch off the 24 V DC power supply to the DP/DP Coupler.
2 Open the front panel door of the DP/DP Coupler.
3 Set the required PROFIBUS address with a screwdriver. The PROFIBUS
address is formed by the sum of all values of the switches in “ON” position
(switch in right position).
4 Set the ADDR DIL switch to the left (“OFF” position).
Result: The PROFIBUS address is read from the DIL switch position, rather
than from the non–volatile memory of the DP/DP Coupler.
5 Switch on the 24 V DC power supply to the DP/DP Coupler.
Result: The DP/DP Coupler applies the PROFIBUS address you have set on
the switch.

DP/DP Coupler
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Example of DIL switch settings

DP/DP Coupler
PROFIBUS address network 1: PROFIBUS address network 2:
DP1 DP2 64
2 64 + 32
+1 32 +2
16
=3 +1
8
4 = 99
2
ADDR = ON: STEP 7 writes the ADDR = OFF: The PROFIBUS
1
PROFIBUS address to the ADDR
address is fetched from the DIL
DP/DP Coupler DIA switch
PS
DIA = OFF: Data validity DIA = ON: Data validity indication
ON ON
indication is disabled is enabled
PS = ON: 24 V DC of network 1 PS = ON: 24 V DC of network 2
is connected is connected

Figure 4-1 Example of DIL switch settings

Changing the PROFIBUS address

You may change the set PROFIBUS address (1 to 125) at any time.

Note
The changes are not applied to the DP/DP Coupler until you have cycled the
24 V DC supply (off/on).

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4.3 Configuring the DP/DP Coupler in STEP 7

Contents

Section Topic Page

4.3.1 Configuring the DP/DP Coupler in STEP 7 4-9
4.3.2 Setting the PROFIBUS address in STEP 7 4-10
4.3.3 Setting the DP/DP Coupler properties in STEP 7 4-11
4.3.4 Example of an I/O configuration for the DP/DP Coupler in STEP 7 4-12

Prerequisites
You require the GSD file SI018070.GS? in order to be able to program the
DP/DP Coupler in STEP 7. Integrate this GSD file into your engineering tool.
This GSD file is included in STEP 7 V5.3 and higher.

GSD file
A GSD file (SI018070.GS?) is available for the DP/DP Coupler. You can download
this file free of charge from the Internet, under:
http://www.ad.siemens.de/csi_e/gsd

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4.3.1 Configuring the DP/DP Coupler in STEP 7

The DP/DP Coupler is programmed in STEP 7 for standard operation. The

DP/DP Coupler requires a configuration for both DP networks, with separate
master systems.

Notice
You need to balance the I/O area of both networks.

Step Activity
1 Start STEP 7 and open HW Config.
2 Drag–and–drop the DP/DP Coupler from the hardware catalog in the folder
PROFIBUS-DP\Further FIELD DEVICES\Gateway\DP/DP Coupler, Release 2
to the PROFIBUS network.
Result: The properties dialog box for the PROFIBUS interface of the
DP/DP Coupler appears.
3 Set the PROFIBUS address of the DP/DP Coupler. This address must
correspond with the PROFIBUS address set on the DP/DP Coupler. Confirm
your entries with OK.
Result: The DP/DP Coupler is added to the DP master system.
4 Now you configure the slots of the DP/DP Coupler
Starting at slot 1, type in the relevant DP IDs for the input or output data. I you
are using I/O data in mixed mode, use a universal DP identifier module.
5 Type in the input and/or output address for each slot.
6 Confirm your entries with “OK”.
Result: You have now configured one side of the DP/DP Coupler.
7 Repeat steps 2 to 6 for the second PROFIBUS DP system connected to the
DP/DP Coupler.
Important
• Network 1 inputs are outputs of network 2,
• Network 1 outputs are inputs of network 1,

Note
Only with configuration of both sides of the DP/DP Coupler
6ES7 158-0AD01-0XA0:
If your slot configuration (of inputs and outputs) is incongruent, the DP/DP Coupler
reports a configuration error to the networks 1 and 2.

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4.3.2 Setting the PROFIBUS address in STEP 7

Requirements
The DP/DP Coupler has been configured in STEP 7(cf. chapter 4.3.1).

Definition
Each bus node must receive a PROFIBUS address so that it can be uniquely
identified on PROFIBUS-DP. The PROFIBUS address is set in STEP 7 separately
for each on of the two PROFIBUS DP networks.
Note:
You can also set the PROFIBUS address directly on the DIL switches of the
DP/DP Coupler (cf. chapter 4.2.4).

Rules
Rules for the assignment of a PROFIBUS address:
• The valid PROFIBUS addresses are: 1 to 125.
• Each PROFIBUS address can only be assigned once in a DP master system.
• You assign a PROFIBUS address to each side of the DP/DP Coupler. It is also
possible to assign the PROFIBUS address for one side of the DP/DP Coupler
directly on the Link, and the other in STEP 7.

Setting the PROFIBUS address in STEP 7

The default PROFIBUS address ”126” is stored in the non–volatile memory of your
DP/DP Coupler.

Step Activity
1 Set the ADDR DIL switch to the left “ON” position.
Result: The PROFIBUS address is fetched from the non–volatile memory area
in the DP/DP Coupler.
2 Switch on the 24 V DC power supply to the DP/DP Coupler.
Result: The LEDs ON1 and/or ON2 are lit.
3 Connect the PG/PC via PG cable to the DP network or to the DP/DP Coupler.
4 Open STEP 7 HW Config and configure the DP/DP Coupler.
5 In HW Config, select the configured DP/DP Coupler.
6 Go to PLC > PROFIBUS > Assign PROFIBUS address.
Result: The “PROFIBUS address” view appears.
7 Enter the configured PROFIBUS address and confirm with “OK”.
Result: The PROFIBUS address is transferred to the non–volatile memory of
the DP/DP Coupler.

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4.3.3 Setting the properties of the DP/DP Coupler in STEP 7

Properties – DP slave
In the ”Configuration“ tab of the ”Properties – DP slave” dialog box, you can set the
following properties:
• “Configuration” tab:
– DP alarm mode: DPV0 or DPV1 slave
– Permit external diagnostics

DPV0 or DPV1 slave

The DP/DP Coupler can only be operated as a DPV1 slave in combination with a
DPV1 master. The additional functions (acyclical services) of a DPV1 slave can
only be used if this is the case.
DP slaves defined as DPV1 slaves in their GSD file can be selected from a
dropdown list for operation in DPV1 or DPV0 mode.

Allow external diagnostics

• Extended diagnostics enabled:
This setting is used in RUN mode. When the DP/DP Coupler reports a
diagnostics event on network 1 (e.g. bus connector on network 1 has been
removed), OB 82 is executed. LED SF2 is lit in addition. The message ”Module
error” is written to the diagnostics buffer of the CPU.
• Extended diagnostics disabled:
This setting is used for commissioning the system. When the DP/DP Coupler
reports a diagnostics event on network 1 (e.g. bus connector on network 1 has
been removed), OB 82 is also executed. LED SF2 is not lit. The system does
not write any dat to the diagnostics buffer of the CPU.
After you commissioned the system, reset the diagnostics function to “Extended
diagnostics enabled”!

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4.3.4 Example of a configuration of the DP/DP Coupler I/O in STEP 7

Introduction
This example shows a typical configuration of the DP/DP Coupler using STEP 7.

Task
The following assumptions have been made for this example:
• Network 1:
– The DP/DP Coupler is assigned PROFIBUS address 4.
– To be transferred to the DP master on network 2:
2 bytes inputs (inconsistent)
16 bytes outputs (inconsistent)
8 bytes inputs (consistent)
2 bytes outputs (consistent)
3 bytes inputs / 5 bytes outputs (consistent)
• Network 2:
– The DP/DP Coupler is assigned PROFIBUS address 24.
– To be transferred to the DP master on network 1:
2 bytes outputs (inconsistent)
16 bytes inputs (inconsistent)
8 bytes outputs (consistent)
2 bytes inputs (consistent)
5 bytes inputs / 3 bytes outputs (consistent)

Configuring the DP/DP Coupler on network 1 in STEP 7

Configuration of the DP/DP Coupler on network 1:

(4) DP/DP Coupler, release 2

Slot DP ID Order no./name Input address Output address Comment

1 16DE 2 bytes input 0...1
2 47 16 bytes output 0...15
3 151 8 bytes input consistent 256...263
4 161 2 bytes output consistent 256...257
5 192 Universal module 2...4 16...20
6

Figure 4-2 Example: Configuration of the DP/DP Coupler on network 1

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Configuring the DP/DP Coupler on network 2 in STEP 7

This DP/DP Coupler configuration must be absolutely congruent to the network 1
configuration. The resultant configuration of the DP/DP Coupler on network 2:

(24) DP/DP Coupler, release 2

Slot DP ID Order no./name Input address Output address Comment

1 16DA 2 bytes output 0...1
2 31 16 bytes input 0...15
3 167 8 bytes output consistent 256...263
4 145 2 bytes intput consistent 256...257
5 192 Universal module 16...20 2...4
6

Figure 4-3 Example: Configuration of the DP/DP Coupler on network 2

4.4 Configuring the DP/DP Coupler with another engineering

tool
Use the GSD file if you prefer to configure the DP/DP Coupler with another
engineering tool such as COM PROFIBUS.

GSD file
A GSD file (SI018070.GS?) is available for the DP/DP Coupler. You can download
this file free of charge from the Internet, under:
http://www.ad.siemens.de/csi_e/gsd

Configuring the DP/DP Coupler

Configure the DP/DP Coupler with your configuration tool (e.g. COM PROFIBUS)
as you would any other DP slave on PROFIBUS-DP.
To do so, load the complete GSD file for the DP/PA link into your configuration tool.

assignment frame
The frame has a length of 15 bytes. Information on the parameter assignment
frame is available on the Internet, under:
http://www.ad.siemens.de/csi_e/gsd

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4.5 Commissioning the DP/DP Coupler

Requirements
Conditions to be met before you commission the DP/DP Coupler:
• You have installed and wired the DP/DP Coupler as described in chapters 2 and
3.
• You have installed both PROFIBUS DP networks. PROFIBUS DP is ready for
operation.
• You have programmed the DP/DP Coupler.

Commission the DP/DP Coupler

Step Activity
1 Switch on the power supply to the DP/DP Coupler.
2 Download the configuration data to the PLC by executing the PLC > Download
to module command.

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Overview of contents

Section Topic Page

5.1 Replacing faulty modules 5-1
5.2 Response times of the DP/DP Coupler 5-1

5.1 Replacement of a faulty DP/DP Coupler

The table below shows you the steps in replacing a faulty DP/DP Coupler.

Step Activity
1 Disconnect the bus connectors from the PROFIBUS DP interfaces.
2 Disconnect the faulty DP/DP Coupler from the power supply.
3 Replace the faulty DP/DP Coupler.
4 Connect the new DP/DP Coupler to the power supply.
5 Connect the PROFIBUS DP interfaces of the new DP/DP Coupler.

5.2 Response times of the DP/DP Coupler

Overview
The chapter below shows you the average time required for the transfer of data
from the DP master on network 1 to the DP master on network 2 via
DP/DP Coupler.

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Operation of the DP/DP Coupler

Response times
The interval expiring between the time data from a DP master are written to the
process image of outputs unit and the time until these can be read in the process
image of the second DP master depends on the following variables:
• CPU scan cycle time of both DP masters
• Bus cycle time of the corresponding DP masters
• Copy cycle within the DP/DP Coupler (TCOPY)
• Overall data length [in bytes] (input/output)

The copy cycle of the DP/DP Coupler is independent of the currently set data
transfer rate.
The following applies:
TCOPY = 1 ms + n x 7 ms
The measurement for the formula above is performed based on the following
criteria:
• CPU 416-2 DP
• Bus cycle time 6 ms
• Data length (n) 1 ... 488 bytes
• Data transfer rate of 12 Mbps
• In the measurement we use neither cyclic diagnostic functions, nor any global
control commands (FREEZE, SYNC).

Note
The copy cycle can usually be neglected when operating at low data transfer
rates.

Factors influencing the response times

The following applies to time–sensitive applications:
• Reduce the amount of data exchanged via the DP/DP Coupler to the minimum.
• Avoid diagnostic data requests at the DP master.
• Do not use any global control command (FREEZE, SYNC) for the DP/DP
Coupler, but rather use a separate group.
• High data transfer rate (12 Mbps).

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Overview of contents
This chapter shows you the meaning of the LED displays on your DP/DP Coupler.
The tables provide information on error states indicated by the LEDs, the possible
causes and suggested corrective measures.
In the next section, you are made familiar with the diagnostic system of the
DP/DP Coupler. An example is used to illustrate the evaluation of a diagnostic
frame.

Section Topic Page

6.1 Diagnostics by means of LEDs 6-2
6.2 Diagnostics Using the User Program 6-4
6.3 Example of a diagnosis 6-11

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6.1 Diagnostics by means of LED indication

SF 1 SF 1: Group error on PROFIBUS DP network 1 (red)

SF 2 SF 2: Group error on PROFIBUS DP network 2 (red)
BF 1 BF 1: Bus error on PROFIBUS DP network 1 (red)
BF 2 BF 2: Bus error on PROFIBUS DP network 1 (red)
ON 1
ON 2
ON 1: 24 V power supply DP/DP Coupler network 1 (green)
ON 2: 24 V power supply DP/DP Coupler network 2 (green)

Figure 6-1 Status / error displays of the DP/DP Coupler

Table 6-1 Meaning of the LEDs ON 1 and ON 2

ON 1 ON 2 Meaning What to do
Off Off • Voltage not present at DP/DP • Switch the power supply
Coupler, module on.
• Applied supply voltage is not • Check the applied voltage.
within permissible range.
• Hardware fault on the DP/DP • Replace the DP/DP Coupler.
Coupler
On Off The DP/DP Coupler is supplied –
with power from network 1.
Off On The DP/DP Coupler is supplied –
with power from network 2.
On On The DP/DP Coupler is supplied –
with power from network 1 and 2.

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 Diagnostics

Table 6-2 Status / error messages of the DP/DP Coupler

LEDs Meaning What to do

ON 1 SF 1 SF 2 BF 1 BF 2
and/o
r ON
2
On On On On On All LEDs come on for –
approximately 1 second.
DP/DP Coupler in startup mode.
On On * * * Diagnostic message on Analyze the diagnostic data.
PROFIBUS DP network 1
On * On * * Diagnostic message on Analyze the diagnostic data.
PROFIBUS DP network 2
On * * On * No connection to DP master on • Verify the correct seating
PROFIBUS DP network 1. of the bus connector.
Possible causes: • Check whether the bus
• Bus communication to the cable to the DP master
DP/DP Coupler is down. has been interrupted.
• The DP master is not in • Switch the 24V DC
operation. switch on the power
s ppl module
supply mod le off and
On * * * On No connection to DP master on
then on again.
PROFIBUS DP network 2.
Possible causes:
• Bus communication to the
DP/DP Coupler is down.
• The DP master is not in
operation.
On * * Fla- * No data exchange between the • Check the configuration.
shes DP master and DP/DP Coupler • Check the PROFIBUS
on PROFIBUS DP network 1. address.
On * * * Fla- No data exchange between the
shes DP master and DP/DP Coupler
on PROFIBUS DP network 2.
Flashes Fla- Fla- Fla- Fla- Internal DP/DP Coupler error Get in touch with your
shes shes shes shes Siemens partner.
*: Not relevant

DP/DP Coupler
A5E00244669-03 6-3
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6.2 Diagnostics by means of the user program

Contents
This chapter describes the structure of the DP/DP Coupler diagnostics system. An
example is used to illustrate the evaluation of a diagnostic frame.

Section Topic Page

6.2.1 Structure of the slave diagnosis 6-4
6.2.2 Standard diagnosis 6-6
6.2.3 Status message (module diagnostics) – only for operation on 6-8
DP master (DPV1) or S7 DP master
6.2.4 Module diagnostics – replacement part mode or on DP master (DPV0) 6-10

Slave diagnosis
Slave diagnosis is performed in accordance with IEC 61784-1:2002 Ed1 CP 3/1.
Depending on the DP master, it can be read out with STEP 7 or other engineering
tools.
In STEP 7, the diagnostic frames of the underlying DP slaves can be displayed in
the online view of the HW Config. See “Diagnosing hardware” in the STEP 7 online
help.
Additional methods of reading out diagnostic information are described in the
SIMATIC Software; Programming with STEP 7 V5.x manual.

6.2.1 Structure of the slave diagnosis

Influencing factors
The structure of slave diagnostics data depends on which DP master the
DP/DP Coupler is operating. The DP/DP Coupler operates either:
• on the DP master (according with DPV0)
• on the DP master (according with DPV1)
• on the S7 DP master
• in replacement part mode for the DP/DP Coupler 6ES7 158-0GG30-0XA0

DP/DP Coupler
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Diagnostic blocks for operation on the DP master (DPV1) or S7 DP master

The table below shows the length of the diagnostic blocks and their start
addresses in the diagnostic frame. The diagnostics blocks have a length of
26 bytes.

Table 6-3 Length and start addresses of the diagnostics blocks for operation on a DP master (DPV1) or
S7 DP master

Diagnostic block Length in bytes Start address

Standard diagnosis 6 0
Reserved 11 6
Status message (module diagnostics) 9 17

Diagnostics blocks for replacement part mode or operation on a DP master

(DPV0)
You obtain these diagnostic blocks,
• If you operate the DP/DP Coupler 6ES7 158-0AD01-0XA0 as DP/DP Coupler
6ES7 158-0AD00-0XA0 as a replacement part with old configuration data.
• if the DP/DP Coupler is operated on a DP master (DPV0).
The table below shows the length of the diagnostic blocks and their start
addresses in the diagnostic frame. The diagnostics blocks have a length of 11
bytes.

Table 6-4 Length and start addresses of the diagnostic blocks in replacement mode

Diagnostic block Length in bytes Start address

Standard diagnosis 6 0
Module diagnostics 5 6

Diagnostic blocks
The structure of diagnostic blocks is described in the following chapters.

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6.2.2 Standard diagnosis

The standard diagnosis consists of 6 bytes and is subdivided as follows:

Byte 0
Byte 1 Station statuses 1 to 3
Byte 2

Byte 3 Master PROFIBUS address

Byte 4
Device identifier
Byte 5

Figure 6-2 Structure of the standard diagnosis

Station status 1 to 3
Station status 1 to 3 provides an overview of the DP/DP Coupler status.

Table 6-5 Structure of station status 1

Bit Meaning Cause/remedy

0 1: The DP master failed to address the • Have you set the correct PROFIBUS
DP/DP Coupler. address on the DP/DP Coupler?
• Is the bus connector connected?
• Voltage on the DP/DP Coupler?
1 1: The DP/DP Coupler is not ready for • Wait until the DP/DP Coupler is in
data exchange. startup mode.
2 1: The DP master has transferred confi- • I/O configuration of both networks is
guration data to the DP/DP Coupler incongruent.
which is inconsistent with the data on
the DP/DP Coupler.
3 1: External diagnosis available. (Group • Analyze the module diagnostic data.
diagnosis display) Bit 3 is reset as soon as all faults
have been rectified. The bit is reset
when there is a new diagnostic
message in the bytes the diagnostics
data mentioned earlier.
4 1: The DP/DP Coupler does not sup- • Check the configuration.
port the requested function (e.g.
modification of the PROFIBUS
address by means of the software).
5 1: The DP master can not interpret the • Check the bus configuration.
answer from the DP/DP Coupler.

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Table 6-5 Structure of station status 1, Fortsetzung

Bit Meaning Cause/remedy

6 1: The configured station type is incon- • Is the correct station type entered in
sistent with the DP/DP Coupler. the configuration software?
7 1: The DP/DP Coupler was configured • The bit is always set to 1 when, for
by another DP-Master (not by the instance, you are accessing the
DP master currently allowed access DP/DP Coupler using the PG or
to the DP/DP Coupler). another DP master.
The PROFIBUS address of the
DP master that has provided the
parameters for the DP/DP Coupler is
located in the diagnostic byte
”Master PROFIBUS address”.

Table 6-6 Structure of station status 2

Bit Meaning
0 1: The DP/DP Coupler must be assigned new parameters.
1 1: A diagnostic message is queued. The DP/DP Coupler can not resume RUN
until the error is rectified (static diagnostic message).
2 1: This bit is always set to ”1”.
3 1: Response monitoring is enabled on the DP/DP Coupler.
4 1: The DP/DP Coupler has received a “FREEZE” control command.
5 1: The DP/DP Coupler has received a “SYNC” control command.
6 0: This bit is always set to “0”.
7 0: This bit is always set to “0”.

Table 6-7 Structure of station status 3

Bit Meaning
0 to 7 0: These bits are always set to “0”.

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Master PROFIBUS address

Byte 3 of the standard diagnostic data contains the PROFIBUS address of the
DP master that has provided the parameters for the DP/DP Coupler and has
read/write access to the DP/DP Coupler.

Device identifier
The device ID is a code that uniquely identifies the DP slave
(PROFIBUS ID number).

Table 6-8 Structure of the device identifier

Byte 4 Byte 5 Designation

80H 70H DP/DP Coupler

6.2.3 Status message (module diagnostics) – only for operation on a

DP master (DPV1) or S7 DP master

The module diagnostics provides detailed information on the DP/DP Coupler.

The structure of module diagnostics is determined by the DP/DP Coupler mode,
i.e. operation on a DP master (DPV1)/S7 DP-Master or in replacement part mode.

Note
Bytes 6 to 16 of the diagnostics dat are reserved!

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Structure of module diagnostics (DPV1 / S7 DP master)

The module diagnostics comprises 9 bytes.

7 6 5 4 3 2 1 0 Bit no.
Byte 17 0 0 0 0 1 0 0 1

Length of the diagnostic blockincluding byte 17

(= 9 bytes)

Code for station diagnosis

Byte 18 81H Status type: Status message

Byte 19 Not applicable
Byte 20 Not applicable

Byte 21 00H: Data invalid

01H: Data valid

Byte 22 Number of inputs (in bytes) of the relevant DP

segment
Byte 23 Number of outputs (in bytes) of the relevant DP
segment

7 6 5 4 3 2 1 0 Bit no.
Byte 24

Reserved
1: The CPU of the other DP network has output a
CLEAR command (sets outputs to “0”)
1: The other segment has changed to UNFREEZE state
1: The other segment has changed to FREEZE state
1: The other segment has changed to UNSYNC state
1: The other segment has changed to SYNC state
Reserved

7 6 5 4 3 2 1 0 Bit no.
Byte 25 0 0 0 0 0 0

1: Power supply PS1 on DP/DP Coupler has failed

(only relevant if the DIL switch “PS” (DP1) is in ON
position)

1: Power supply PS2 on DP/DP Coupler has fai-

led (only relevant if the DIL switch “PS” (DP2) is
in ON position)

Figure 6-3 Structure of module diagnostics (DPV1 / S7 DP master)

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6.2.4 Module diagnostics - replacement part mode or operation on a

DP master (DPV0)

Structure of module diagnostics (replacement part mode or operation on a

DP master (DPV0))
The module diagnostics comprises 5 bytes.

7 6 5 4 3 2 1 0 Bit no.
Byte 6 0 0 0 0 0 1 0 1

Length of the diagnostic blockincluding byte 6

(= 5 bytes)

Code for station diagnosis

Byte 7 00H: Data from other segment are invalid

01H: Data from other segment are valid

Byte 8 Number of inputs (in bytes) of the relevant DP

segment
Byte 9 Number of outputs (in bytes) of the relevant DP
segment

7 6 5 4 3 2 1 0 Bit no.
Byte 10

Reserved
1: The CPU of the other DP network has output a
CLEAR command (sets outputs to “0”)
1: The other segment has changed to UNFREEZE state
1: The other segment has changed to FREEZE state
1: The other segment has changed to UNSYNC state
1: The other segment has changed to SYNC state
Reserved

Figure 6-4 Structure of module diagnostics (replacement part mode or operation on a

DP master (DPV0))

DP/DP Coupler
6-10 A5E00244669-03
 Diagnostics

6.3 Example of a diagnosis

Introduction
This practical example shows the call of a diagnostic function on the
DP/DP Coupler:

Section Topic Page

6.3.1 Task 6-11
6.3.2 Solution with STEP 7 6-12

6.3.1 Task

The following assumptions have been made for this example:

• The DP/DP Coupler is assigned diagnostics address 1022 (corresponds with
3FEH).
• Figure 6-5 shows an example of the structure for diagnostic data analysis.

DP master work 1 DP master work 2

PROFIBUS address 4 PROFIBUS address 10

28 byte input data 52 byte input data

52 byte output data 28 byte output data

DP/DP Coupler

Figure 6-5 Example of the analysis of diagnostics data from the DP/DP Coupler

DP/DP Coupler
A5E00244669-03 6-11
Diagnostics

6.3.2 Solution with STEP 7

Call of the SFC 13

To read the diagnostic data of the DP/DP Coupler, call SFC 13 (DPNRM_DG) in
OB 1.

Table 6-9 Call of the SFC 13 (DPNRM_DG) in the OB 1

STL Explanation
CALL SFC 13
REQ :=TRUE //Request to read the diagnostic data
LADDR :=W#16#3FE //Diagnostics address
RET_VAL :=MW0 //RET_VAL of SFC 13
RECORD :=P#DB10.DBX 0.0 BYTE 26 //Data mailbox for the diagnosis in DB10
BUSY :=M2.0 //Read operation runs through several OB1
cycles

With this call, the diagnostic data are stored in DB 10.

Appearance of DB 10
Define the following structure for DB 10:

Address Name Type Initial value Comment

0.0 STRUCT
+0.0 Norm_Diag ARRAY[1..6] Standard diagnosis
*1.0 BYTE
+17.0 Status_Message ARRAY[1..9] Status message
*1.0 BYTE
=26.0 END_STRUCT

DP/DP Coupler
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 Diagnostics

Content of DB10
The relevant diagnostic data in DB 10 have the following meanings:

Table 6-10 Example: Analysis of the diagnostics data

Diagnostics DP master Meaning DP master Meaning

address network 1 network 2
DB10.DBB0 00H Station status 1 00H
DB10.DBB1 0CH Station status 2: Response 0CH Station status 2: Response
monitoring enabled monitoring enabled
DB10.DBB2 00H Station status 3 00H Station status 3
DB10.DBB3 04H PROFIBUS address of the 0AH PROFIBUS address of the
DP master on network 1 DP master on network 2
DB10.DBB4 80H Device ID of the 80H Device ID of the
DP/DP Coupler
C l DP/DP Coupler
C l
DB10.DBB5 70H 70H
DB10.DBB6 Reserved Reserved
to
DB10.DBB16
DB10.DBB17 09H Code and length of module 09H Code and length of module
diagnostics data diagnostics data
DB10.DBB18 81H Status message (fixed) 81H Status message (fixed)
DB10.DBB19 Reserved Reserved
DB10.DBB20 Reserved Reserved
DB10.DBB21 01H Data from network 2 are valid 01H Data from network 1 are valid
DB10.DBB22 34H 52 bytes input data from 1CH 28 bytes input data from
network 2 network 1
DB10.DBB23 1CH 28 bytes output data from 34H 52 bytes output data from
network 2 network 1
DB10.DBB24 14H The network 2 node is in 16H The network 1 node is in
UNSYNC, UNFREEZE mode UNSYNC, UNFREEZE, and
CLEAR mode
DB10.DBB25 00H Power supply present on both 00H Power supply present on both
DP/DP Coupler segments DP/DP Coupler segments

Result
The network 1 data are valid, the network 1 DP master has switched its stations to
CLEAR mode (e.g. CPU of network is in STOP).

DP/DP Coupler
A5E00244669-03 6-13
Diagnostics

DP/DP Coupler
6-14 A5E00244669-03
Technical data A
Overview of contents
This chapter provides general technical data and the technical data of the
DP/DP Coupler:

Section Topic Page

A.1 General technical data A-1
A.2 Technical data of the DP/DP coupler (6ES7 158-0AD01-0XA0) A-12
A.3 Use of the DP/DP Coupler in potentially explosive environments of A-13
Zone 2 (in all official EU languages)

A.1 General technical data

What are general technical data?

The general technical data consist of:
• the standards and test values that the described components must comply with
and fulfil.
• the test criteria by which the described components were tested.

Section Topic Page

A.1.1 Standards and approvals A-2
A.1.2 Electromagnetic compatibility A-6
A.1.3 Transportation and storage conditions A-8
A.1.4 Mechanical and climatic ambient conditions for operation A-9
A.1.5 Data on insulation tests, protection class and degree of protection A-11
A.1.6 Rated voltage A-11

DP/DP Coupler
A5E00244669-03 A-1
Technical data

A.1.1 Standards and approvals

CE certification
The described components fulfil the requirements and safety objectives of the
following EC Directives and comply with the harmonized European standards (EN)
published for programmable logic controllers in the official journals of the EC:
• 73/23/EEC Low Voltage Directive (for electrical equipment)
• 89/336/EEC Electromagnetic Compatibility Directive (EMC Directive)
• Directive 94/9/EC on protective devices and systems for use in potentially
explosive areas (explosion protection directive)

The EC Declarations of Conformity are available for the relevant authorities at the
following address:
Siemens Aktiengesellschaft
Automation and Drives
A&D AS RD ST Type Test
PO Box 1963
D-92209 Amberg

DP/DP Coupler
A-2 A5E00244669-03
 Technical data

Approvals
Underwriters Laboratories Inc. to
 UL 508 (Industrial Control Equipment)
 CSA C22.2 No. 142 (Process Control Equipment)

Or

Underwriters Laboratories Inc. to

 UL 508 (Industrial Control Equipment)

HAZ. LOC.  CSA C22.2 No. 142 (Process Control Equipment)

 UL 1604 (Hazardous Location)
 CSA-213 (Hazardous Location)
APPROVED for use in
Class I, Division 2, Group A, B, C, D T4;
Class I, Zone 2, AEx nC, Group IIC T4

Note
The approvals currently effective are found on the rating plate of each module.

FM approval
Factory Mutual Research (FM) in accordance with
Approval Standard Class Number 3611, 3600, 3810
APPROVED for use in
Class I, Division 2, Group A, B, C, D T4;
Class I, Zone 2, Group IIC T4

to EN 50021 (Electrical apparatus for potentially explosive atmospheres; Type

of protection “n”)

II 3 G EEx nA II T4

Label for Australia

The described components comply with the requirements of the
AS/NZS 2064 (Class A) standard.

DP/DP Coupler
A5E00244669-03 A-3
Technical data

IEC 61131
The described components comply with the requirements and criteria of the IEC
61131-2 standard (programmable logic controllers, Part 2: Equipment requirements
and tests).

Marine approval (pending)

Classification societies:
• ABS (American Bureau of Shipping)
• BV (Bureau Veritas)
• DNV (Det Norske Veritas)
• GL (Germanischer Lloyd)
• LRS (Lloyds Register of Shipping)
• Class NK (Nippon Kaiji Kyokai)

PROFIBUS standard
The components described are based on the standard IEC 61784-1:2002 Ed1
CP 3/1.

Use in industrial environments

SIMATIC products are designed for use in industry.

Table A-1 Use in industrial environments

Area of application Requirements

Emitted interference Noise immunity
Industry EN 61000-6-4:2001 EN 61000-6-2:2001

DP/DP Coupler
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 Technical data

Use in residential areas

If you use the described components in residential areas, you must ensure that
they comply with limit value class B to EN 55011 with respect to radio interference.
Measures suitable for achieving the radio interference level required by limit value
class B are:
• Installation in grounded switch cabinets / cubicles
• Use of filters in supply lines

Warning
! There is a risk of injury and damage to property.
In areas where there is a risk of explosion, injuries and damage may be caused if
you remove connectors during operation.
In potentially explosive environments, always switch of the power supply before
you disconnect any component connectors.

DP/DP Coupler
A5E00244669-03 A-5
Technical data

A.1.2 Electromagnetic compatibility

Introduction
This chapter contains data on the noise immunity and RF suppression of the
described components.
The described components meet the requirements of the European EMC
legislation for the single market.

Pulse-type interference
The table below shows the electromagnetic compatibility of the described
components with respect to pulse-type interference. The prerequisite for this is that
the system meets and complies with the relevant requirements and guidelines
relating to electrical equipment.

Table A-2 Pulse-type interference

Pulse-type interference Tested at Corresponds to

severity of
Electrostatic discharge in accordance with 8 kV 3 (air discharge)
IEC 61000-4-2 4 kV 2 (contact
discharge)
Burst impulse (rapid transient 2 kV (supply line) 3
interference) in accordance with IEC 2 kV (signal line)
61000-4-4
High energy single pulse (surge) in accordance with IEC 61000-4-5
External RC circuit is required (see installation manual entitled Automation System S7-300,
Installation, Section “Lightning protection and surge protection”)
• Asymmetric interference 2 kV (supply line)
2 kV (signal line/
data line) 3
• Symmetric interference 1 kV (supply line)
1 kV (signal line/
data line)

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 Technical data

Sinusoidal interference
The table below shows the EMC behavior of the described components with
respect to sinusoidal interference.

Table A-3 Sinusoidal interference

Sinusoidal interference Test values Corres-

ponds to
severity of
RF radiation (electromagnetic fields) in 10 V/m with 80 % amplitude modulation of
accordance with IEC 61000-4-3 1 kHz in the range 80 MHz to 1000 MHz 3
10 V/m with 50 % pulse modulation at 900 MHz
RF interference on cables and cable Test voltage of 10 V with 80 % amplitude
shields in accordance with modulation of 1 kHz in the range 9 kHz to 3
IEC 61000-4-6 80 MHz

Emission of radio interference

Emitted interference from electromagnetic fields in accordance with EN 55011: limit
value class A, group 1

From 30 to 230 MHz < 30 dB (mV/m)Q

From 230 to 1000 MHz < 37 dB (mV/m)Q
Measured at 30 m distance

Emitted interference via a.c. supply in accordance with EN 55011: limit value class
A, group 1

From 0.15 to 0.5 MHz < 79 dB (mV)Q

< 66 dB (mV)M
From 0.5 to 5 MHz < 73 dB (mV)Q
< 60 dB (mV)M
From 5 to 30 MHz < 73 dB (mV)Q
< 60 dB (mV)M

DP/DP Coupler
A5E00244669-03 A-7
Technical data

A.1.3 Transportation and storage conditions

Transport and storage of modules

The described components exceed the requirements of IEC 61131, Part 2, as
regards transportation and storage requirements. The following values apply to
modules that are transported or stored in the original packaging.

Table A-4 Transportation and storage conditions

Type of condition Permissible range

Free fall (in transport packaging) v 0.3 m
Temperature from –40
C to + 70
C
Air pressure From 1080 to 660 hPa (corresponds to a
height of –1000 to 3500 m)
Relative air humidity From 10 to 95 %, without condensation
Sinusoidal vibrations in accordance with 5 - 9 Hz: 3.5 mm
IEC 60068-2-6 9 - 150 Hz: 9.8 m/s2
Shock in accordance with IEC 60068-2-29 250 m/s2, 6 ms, 1000 shocks

DP/DP Coupler
A-8 A5E00244669-03
 Technical data

A.1.4 Mechanical and climatic ambient conditions for operation

Operating conditions
The described components are designed for use in a fixed, sheltered location. The
operating conditions exceed the requirements of IEC 61131 Part 2.
The described components meet the operating conditions of Class 3C3 in
accordance with DIN EN 60721 Part 2.

Use with additional measures

Without additional measures, the described components may not be used:
• in locations with a high proportion of ionizing radiation
• in locations with operating conditions that are severe on account of the
following, for example:
– dust
– corrosive vapors or gases
– strong electrical or magnetic fields
• in systems that require special monitoring, such as:
– lift systems
– electrical systems in especially endangered areas
An additional measure could be, for example, the installation in a cabinet or in an
enclosure.

Mechanical ambient conditions

The mechanical ambient conditions for the described components are specified for
sinusoidal vibrations in the following table.

Table A-5 Mechanical ambient conditions

Frequency range Continuous Occasional

in Hz
10 v f v 58 0.0375 mm amplitude 0.075 mm amplitude
58 v f v 150 0.5 g constant acceleration 1 g constant acceleration

Vibration reduction
When the described components are subjected to major shocks or vibrations, you
must take suitable action to reduce the acceleration or amplitude.
We recommend mounting the described components on damping material (e.g. on
rubber-metal connections).

DP/DP Coupler
A5E00244669-03 A-9
Technical data

Tests for mechanical ambient conditions

The following table provides information on the type and scope of the tests for
mechanical ambient conditions.

Table A-6 Test for mechanical ambient conditions

Test for ... Test standard Comments

Vibrations Oscillations tested in Vibration type:
accordance with IEC frequency sweeps with a rate of change of 1
60068, Parts 2–6 octave per minute.
(sine) 10 Hz v f v 58 Hz, constant amplitude
0.075 mm
58 Hz v f v 150 Hz, constant acceleration 1 g
Vibration duration: 10 frequency sweeps per
axis in each of the 3 vertically arranged axes
Shock Shock test in Type of shock: half-sine
accordance with Strength of shock:
IEC 60068 Part 2-29 15 g peak value, 11 ms duration
Shock direction:
3 shocks in both + and – direction in each of the
3 vertically arranged axes

Climatic environmental conditions

The components described may be used under the following climatic ambient
conditions:

Table A-7 Climatic ambient conditions

Ambient conditions Permissible range

Temperature:
vertical mounting position: from 0 to 60
C
all other mounting positions from 0 to 40
C
Relative humidity From 10 to 95 %,
Air pressure From 1080 to 795 hPa
Contaminant concentration SO2: < 0.5 ppm;
RH < 60 %, no condensation
H2S: < 0.1 ppm;
RH < 60 %, no condensation

DP/DP Coupler
A-10 A5E00244669-03
 Technical data

A.1.5 Data on insulation tests, protection class and degree of

protection

Test voltages
The insulating properties are verified in individual testing with the following test
voltages:

Table A-8 Test voltages

Circuits with a rated voltage of Ue against Test voltage

other circuits or ground
0 V < Ue v 50 V 600 VDC, 1 s

Protection class
Protection class I in accordance with IEC 60536, i. e. PE connection to rail is
required!

Protection against solid bodies and water

Protection type IP 20 in accordance with IEC 60529; i.e. protection against contact
with standard probes.
The device is not water–proof.

A.1.6 Rated voltage

Rated voltages for operation

The described components work with a rated voltage of 24 VDC. The tolerance
range lies between 20.4 and 28.8 VDC.

DP/DP Coupler
A5E00244669-03 A-11
Technical data

A.2 Technical data of the DP/DP Coupler

(6ES7 158-0AD01-0XA0)
Dimensions and weight Insulation tested at 500 VDC
Dimensions 40 127 117 Power input typically 90 mA
W H D (mm)
Power loss Typically 2 W
Weight Approx. 250 g
Status, interrupts, diagnostics
Module-specific data
Status display No
Transmission speed 9,6; 19,2; 45,45; 93,75;
Interrupts No
187,5; 500 kbps
1,5; 3, 6, 12 Mbps Diagnostic function Yes
Bus protocol PROFIBUS DP • Group error red LED ”SF1”
PROFIBUS DP
Frame length of I/O data max.
network 1
244 bytes inputs /
244 bytes outputs • Group error red LED ”SF2”
PROFIBUS DP
Diagnostic frame length Max. 26 bytes
network 2
Parameter assignment Max. 15 bytes
• Bus error red LED ”BF1”
frame length
PROFIBUS DP
Suitable for system No network 1
changes during
• Bus error red LED ”BF2”
operation:
PROFIBUS DP
Voltages, currents, potentials network 2
Rated supply voltage 24 VDC • 24 V DC monitoring green LED ”ON1”
(20.4 V ... 28.8 V) on network 1
• Polarity reversal Yes • 24 V DC monitoring green LED ”ON2”
protection on network 2
• Power failure Min. 5 ms
bridging
Galvanic isolation of the 24 V power supply
• to PROFIBUS-DP Yes
• between each other Yes

DP/DP Coupler
A-12 A5E00244669-03
 Technical data

A.3 Use of the DP/DP Coupler in potentially explosive

environments of Zone 2 (in all official EU languages)
In the following sections you will find important information in all official EU
languages.

Chapter overview

Section Topic
A.3.1 Einsatz der Buskopplung DP/PA im explosionsgefährdeten Bereich Zone 2
A.3.2 Use of the DP/DP Coupler in potentially explosive environments of Zone 2
A.3.3 Utilisation du coupleur de bus DP/PA dans un environnement à risque
d’explosion en zone 2
A.3.4 Aplicación del acoplamiento de bus DP/PA en áreas con peligro de explosión,
zona 2
A.3.5 Impiego dell’accoppiamento di bus DP/PA nell’area a pericolo di esplosione
zona 2
A.3.6 Gebruik van de buskoppeling DP/PA in het explosieve gebied zone 2
A.3.7 Brug af buskoblingen DP/PA i det eksplosionfarlige område zone 2
A.3.8 Väyläkytkennän DP/PA käyttö räjähdysvaarannetuilla alueilla, vyöhyke 2
A.3.9 Användning av bussanslutning DP/PA i explosionsriskområde zon 2
A.3.10 Uso do acoplamento de bus DP/PA em área exposta ao perigo de explosão,
zona 2
A.3.11 Χρηση τηζ συσΚευηζ διαυλου DP/PA σε ...

DP/DP Coupler
A5E00244669-03 A-13
Technical Data

A.3.1 Einsatz des DP/DP-Kopplers im explosionsgefährdeten

Bereich Zone 2

Zone 2
Explosionsgefährdete Bereiche werden in Zonen eingeteilt. Die Zonen werden nach der
Wahrscheinlichkeit des Vorhandenseins einer explosionsfähigen Atmosphäre unter-
schieden.
Zone Explosionsgefahr Beispiel
2 explosive Gasatmosphäre tritt Bereiche um Flanschverbindungen mit Flach-
nur selten und kurzzeitig auf dichtungen bei Rohrleitungen in geschlossenen
Räumen
sicherer nein • außerhalb der Zone 2
Bereich • Standardanwendungen von dezentraler
Peripherie

Nachfolgend finden Sie wichtige Hinweise für die Installation des DP/DP-Kopplers im
explosionsgefährdeten Bereich.

Weitere Informationen
Weitere Informationen zum DP/DP-Koppler und zu den verschiedenen Komponenten
finden Sie im Handbuch.

Fertigungsort
Siemens AG, Bereich A&D
Werner-von-Siemens-Straße 50
92224 Amberg
Germany

Zulassung

II 3 G EEx nA II T4 nach EN 50021 : 1999

Prüfnummer: KEMA 02ATEX1096 X

Hinweis
Baugruppen mit der Zulassung II 3 G EEx nA II T4 dürfen nur in
Automatisierungssysteme SIMATIC S5/S7 / DP-Slaves der Gerätekategorie 3G
eingesetzt werden.

DP/DP Coupler
A-14 A5E00224669-03
 Technical Data

Instandhaltung
Für eine Reparatur muss die betroffene Komponente an den Fertigungsort geschickt
werden. Nur dort darf die Reparatur durchgeführt werden.

Besondere Bedingungen
1. Der DP/DP-Koppler muss in einen Schaltschrank oder ein metallisches Gehäuse
eingebaut werden. Diese müssen mindestens die Schutzart IP 54 (nach EN 60529)
gewährleisten. Dabei sind die Umgebungsbedingungen zu berücksichtigen, in denen
das Gerät installiert wird. Für das Gehäuse muss eine Herstellererklärung für Zone 2
vorliegen (gemäß EN 50021).
2. Wenn am Kabel bzw. an der Kabeleinführung dieses Gehäuses unter Betriebs-
bedingungen eine Temperatur > 70 °C erreicht wird oder wenn unter Betriebs-
bedingungen die Temperatur an der Aderverzweigung > 80 °C sein kann, müssen die
Temperatureigenschaften der Kabel mit den tatsächlich gemessenen Temperaturen
übereinstimmen.
3. Die eingesetzten Kabeleinführungen müssen der geforderten IP-Schutzart und dem
Abschnitt 7.2 (gemäß EN 50021) entsprechen.
4. Alle Geräte, einschließlich Schalter etc., die an den Ein- und Ausgängen des
DP/DP-Koppler angeschlossen werden, müssen für den Explosionsschutz
Typ EEx nA oder EEx nC genehmigt sein.
5. Es müssen Maßnahmen getroffen werden, dass die Nennspannung durch
Transienten um nicht mehr als 40 % überschritten werden kann.
6. Umgebungstemperaturbereich: 0° C bis 60° C
7. Innerhalb des Gehäuses ist an einem nach dem Öffnen gut sichtbaren Platz ein Schild
mit folgender Warnung anzubringen:
Warnung
Das Gehäuse darf nur kurze Zeit geöffnet werden, z. B. für visuelle Diagnose.
Betätigen Sie dabei keine Schalter, ziehen oder stecken keine Baugruppen und
trennen keine elektrischen Leitungen (Steckverbindungen).
Diese Warnung kann unberücksichtigt bleiben, wenn bekannt ist, dass keine
explosionsgefährdete Atmosphäre herrscht.

Liste der zugelassenen Baugruppen

Die Liste mit den zugelassenen Baugruppen finden Sie im Internet:
http://www4.ad.siemens.de/WW/view/de/13702947.

DP/DP Coupler
A5E00224669-03 A-15
Technical Data

A.3.2 Use of the DP/DP Coupler in a Zone 2 Hazardous Area

Zone 2
Hazardous areas are divided up into zones. The zones are distinguished according to the
probability of the existence of an explosive atmosphere.
Zone Explosion Hazard Example
2 Explosive gas atmosphere Areas around flange joints with flat gaskets in
occurs only seldom and for a pipes in enclosed spaces
short time
Safe area No • Outside zone 2
• Standard distributed I/O applications

Below you will find important information on the installation of the components of the
DP/DP coupler in a hazardous area.

Further Information
You will find further information on the DP/DP coupler and the various components in the
manual.

Production Location
Siemens AG, Bereich A&D
Werner-von-Siemens-Straße 50
92224 Amberg
Germany

Certification

II 3 G EEx nA II T4 to EN 50021 : 1999

Test number: KEMA 02ATEX1096 X

Note
Modules with II 3 G EEx nA II T4 certification can only be used in
SIMATIC S5/S7 / DP Slave automation systems belonging to equipment
category 3G.

DP/DP Coupler
A-16 A5E00224669-03
 Technical Data

Maintenance
If repair is necessary, the affected component must be sent to the production location.
Repairs can only be carried there.

Special Conditions
1. The DP/DP coupler must be installed in a cabinet or metal housing. These must
comply with the IP 54 degree of protection as a minimum. The environmental
conditions under which the equipment is installed must be taken into account. There
must be a manufacturer's declaration for zone 2 available for the housing (in
accordance with EN 50021).
2. If a temperature of > 70 °C is reached in the cable or at the cable entry of this housing
under operating conditions, or if a temperature of > 80 °C can be reached at the
junction of the conductors under operating conditions, the temperature-related
properties of the cables must correspond to the temperatures actually measured.
3. The cable entries used must comply with the required IP degree of protection and
Section 7.2 (in accordance with EN 50021).
4. All devices (including switches, etc.) that are connected to the inputs and outputs of a
DP/DP coupler must be approved for EEx nA or EEx nC explosion protection.
5. Steps must be taken to ensure that the rated voltage through transients cannot be
exceeded by more than 40 %.
6. Ambient temperature range: 0° C to 60° C
7. A sign containing the following warning must be put up inside the housing in an easily
visible position when the housing is opened:
Warning
The housing can only be opened for a short time (e.g. for visual diagnostics). If you do
this, do not operate any switches, remove or install any modules or disconnect any
electrical cables (plug-in connections).
You can disregard this warning if you know that the atmosphere is not hazardous (i.e.
there is no risk of explosion).

List of Approved Modules

You will find the list of approved modules on the Internet:
http://www4.ad.siemens.de/WW/view/en/13702947.

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Technical Data

A.3.3 Utilisation du coupleur DP/DP dans un environnement à

risque d'explosion en zone 2

Zone 2
Les environnements à risque d'explosion sont répartis en zones. Les zones se
distinguent par la probabilité de présence d'une atmosphère explosive.
Zone Risque d'explosion Exemple
2 Formation rare et brève d'une Environnement de raccords à joints plats dans le
atmosphère gazeuse explosive cas de conduites dans des locaux fermés
Zone sûre Non • A l'extérieur de la zone 2
• Utilisation standard de périphérie décentralisée

Vous trouverez ci-après des remarques importantes pour l'installation des composantes
du coupleur DP/DP dans un environnement à risque d'explosion.

Informations complémentaires
Des informations complémentaires sur le coupleur DP/DP et les diverses composantes
se trouvent dans le manuel.

Lieu de production
Siemens AG, Bereich A&D
Werner-von-Siemens-Straße 50
92224 Amberg
Germany

Homologation

II 3 G EEx nA II T4 selon EN 50021 : 1999

Numéro de contrôle : KEMA 02ATEX1096 X

Nota
Les modules homologués II 3 G EEx nA II T4 ne peuvent être utilisés que
dans des automates SIMATIC S5/S7 / esclaves DP de catégorie 3G.

DP/DP Coupler
A-18 A5E00224669-03
 Technical Data

Entretien
Si une réparation est nécessaire, la composante concernée doit être expédiée au lieu de
production. La réparation ne doit être effectuée qu'en ce lieu.

Conditions particulières
1. Le coupleur DP/DP doit être installé dans une armoire ou un boîtier métallique. Ceux-
ci doivent assurer au moins l'indice de protection IP 54. Il faut alors tenir compte des
conditions d'environnement dans lesquelles l'appareil est installé. Le boîtier doit faire
l’objet d’une déclaration de conformité du fabricant pour la zone 2 (selon EN 50021).
2. Si dans les conditions d’exploitation, une température > 70 °C est atteinte au niveau
du câble ou de l’entrée du câble dans ce boîtier, ou bien si la température au niveau
de la dérivation des conducteurs peut être > 80 °C, les capacités de résistance
thermique des câbles doivent corespondre aux températures effectivement mesurées.
3. Les entrées de câbles utilisées doivent avoir le niveau de protection IP exigé et être
conformes au paragraphe 7.2 (selon EN 50021).
4. Tous les appareillages (y compris les interrupteurs, etc.) raccordés aux entrées et
sorties du coupleur DP/DP doivent être homologués pour la protection antidéflagrante
type EEx nA ou EEx nC.
5. Il faut prendre des mesures pour que la tension nominale ne puisse pas être
dépassée de plus de 40% sous l’influence de transitoires.
6. Plage de température ambiante : 0° C à 60° C
7. A l’intérieur du boîtier, il faut placer, à un endroit bien visible après ouverture, une
plaquette comportant l’avertissement suivant :
Avertissement
Ouvir le boîtier le moins longtemps possible, par exemple pour effectuer un diagnostic
visuel. Ce faisant, n’actionnez aucun commutateur, ne déconnectez aucun module et
ne débanchez pas de câbles électriques (connexions).
Le respect de cet avertissement n’est pas impératif s’il est certain que l’environnement
ne présente pas de risque d’explosion.

Liste des modules homologués

Vous trouverez sur Internet la liste des modules homologués :
http://www4.ad.siemens.de/WW/view/fr/13702947.

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A.3.4 Aplicación del acoplador DP/DP en áreas con peligro de

explosión, zona 2

Zona 2
Las áreas con peligro de explosión se clasifican en zonas. Las zonas se diferencian
según la probabilidad de la existencia de una atmósfera capaz de sufrir una explosión.
Zona Peligro de explosión Ejemplo
2 La atmósfera explosiva de gas Áreas alrededor de uniones abridadas con juntas
sólo se presenta rara vez y muy planas en tuberías en locales cerrados
brevemente
Área segura no • fuera de la zona 2
• Aplicaciones estándar de la periferia
descentralizada

A continuación encontrará importantes informaciones para la instalación de los

componentes del acoplador DP/DP en áreas con peligro de explosión.

Otras informaciones
Encontrará otras informaciones relativas al acoplador DP/DP y a los distintos
componentes en el Manual.

Lugar de fabricación
Siemens AG, Bereich A&D
Werner-von-Siemens-Straße 50
92224 Amberg
Germany

Homologación

II 3 G EEx nA II T4 según norma EN 50021 : 1999

Número de comprobación: KEMA 02ATEX1096 X

Nota
Los módulos con la homologación II 3 G EEx nA II T4 pueden utilizarse
únicamente en los autómatas programables SIMATIC S5/S7/ esclavos DP de la
categoría de equipo 3G.

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Mantenimiento
Para una reparación se ha de remitir el componente afectado al lugar de fabricación.
Sólo allí se puede realizar la reparación.

Condiciones especiales
1. El acoplador DP/DP se ha de montar en un armario eléctrico de distribución o en una
carcasa metálica. Éstos deben garantizar como mínimo el grado de protección IP 54.
Para ello se han de tener en cuenta las condiciones ambientales, en las cuales se
instala el equipo. La caja deberá contar con una declaración del fabricante para la
zona 2 (conforme a EN 50021).
2. Si durante la operación se alcanzara una temperatura > 70° C en el cable o la entrada
de cables de esta caja o bien una temperatura > 80° C en la bifurcación de hilos,
deberán adaptarse las propiedades térmicas de los cables a las temperaturas
medidas efectivamente.
3. Las entradas de cable utilizadas deben cumplir el grado de protección IP exigido y lo
expuesto en el apartado 7.2 (conforme a EN 50021).
4. Todos los dispositivos –inclusive interruptores, etc.– conectados a las entradas y
salidas del acoplador DP/DP deben estar homologados para la protección contra
explosiones del tipo EEx nA o EEx nC.
5. Es necesario adoptar las medidas necesarias para evitar que la tensión nominal
pueda rebasar en más del 40 % debido a efectos transitorios.
6. Margen de temperatura ambiente: 0° C hasta 60° C
7. Dentro de la caja deberá colocarse en un lugar perfectamente visible tras su apertura
un rótulo con la siguiente advertencia:
Precaución
Abrir la caja sólo brevemente, p.ej. para el diagnóstico visual. Durante este tiempo
Ud. no deberá activar ningún interruptor, desenchufar o enchufar módulos ni separar
conductores eléctricos (conexiones enchufables).
Esta advertencia puede ignorarse si Ud. sabe que en la atmósfera existente no hay
peligro de explosión.

Lista de los módulos homologados

En la internet hallará Ud. una lista con los módulos homologados:
http://www4.ad.siemens.de/WW/view/es/13702947.

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A.3.5 Impiego dell'accoppiatore di bus DP/DP nell'area a pericolo di

esplosione zona 2

Zona 2
Le aree a pericolo di esplosione vengono suddivise in zone. Le zone vengono distinte
secondo la probabilità della presenza di un'atmosfera esplosiva.
Zona Pericolo di esplosione Esempio
2 L'atmosfera esplosiva si Aree intorno a collegamenti a flange con
presente solo raramente e guarnizioni piatte nelle condotte in ambienti chiusi
brevemente
Area sicura No • Al di fuori della zona 2
• Applicazioni standard di periferia decentrata

Qui di seguito sono riportate delle avvertenze importanti per l'installazione dei
componenti dell'accoppiatore di bus DP/DP nell'area a pericolo di esplosione.

Ulteriori informazioni
Ulteriori informazioni sull'accoppiatore di bus DP/DP e sui diversi componenti si trovano
nel manuale.

Luogo di produzione
Siemens AG, Bereich A&D
Werner-von-Siemens-Straße 50
92224 Amberg
Germany

Autorizzazione

II 3 G EEx nA II T4 secondo EN 50021 : 1999

Numero di controllo: KEMA 02ATEX1096 X

Avvertenza
Le unità con l'autorizzazione II 3 G EEx nA II T4 possono essere impiegate
solo nei controllori programmabili SIMATIC S5/S7 / slave DP della categoria di
apparecchiature 3G.

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Manutenzione
Per una riparazione, il componente interessato deve essere inviato al luogo di
produzione. La riparazione può essere effettuata solo lì.

Condizioni particolari
1. L'accoppiatore di bus DP/DP deve essere montato in un armadio elettrico o in un
contenitore metallico. Questi devono assicurare almeno il tipo di protezione IP 54. In
questo caso bisogna tenere conto delle condizioni ambientali nelle quali
l'apparecchiatura viene installata. Per il contenitore deve essere presente una
dichiarazione del costruttore per la zona 2 (secondo EN 50021).
2. Se nei cavi o nel loro punto di ingresso in questo contenitore viene raggiunta in
condizioni di esercizio una temperatura > 70 °C o se in condizioni di esercizio la
temperatura nella derivazione dei fili può essere > 80 °C, le caratteristiche di
temperatura dei cavi devono essere conformi alla temperatura effettivamente
misurata.
3. Gli ingressi dei cavi usati devono essere conformi al tipo di protezione richiesto e alla
sezione 7.2 (secondo EN 50021).
4. Tutte le apparecchiature, inclusi interruttori, ecc. che vengono collegati agli
ingressi/uscite dell'accoppiatore di bus DP/DP, devono essere state omologate per la
protezione da esplosione tipo EEx nA o EEx nC.
5. Devono essere prese delle misure per evitare che la tensione nominale possa essere
superata per più del 40% da parte di transienti.
6. Campo termico ambientale: da 0° C a 60° C
7. All’interno del contenitore va apportata, in un luogo ben visibile dopo l’apertura, una
targhetta con il seguente avvertimento:
Attenzione
Il contenitore può rimanere aperto solo per breve tempo, ad esempio per una
diagnostica a vista. In tal caso non azionare alcun interruttore, non disinnestare o
innestare unità e non staccare connessioni elettriche (connettori).
Non è necessario tenere conto di questo avvertimento se è noto che non c’è
un’atmosfera a rischio di esplosione.

Elenco delle unità abilitate

La lista con le unità omologate si trova in Internet al sito:
http://www4.ad.siemens.de/WW/view/it/13702947.

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A.3.6 Gebruik van de buskoppeling DP/DP in het explosieve

gebied zone 2

Zone 2
Explosieve gebieden worden ingedeeld in zones. Bij de zones wordt onderscheiden
volgens de waarschijnlijkheid van de aanwezigheid van een explosieve atmosfeer.
Zone Explosiegevaar Voorbeeld
2 Een explosieve gasatmosfeer Gebieden rond flensverbindingen met pakkingen
treedt maar zelden op en voor bij buisleidingen in gesloten vertrekken
korte duur
Veilig neen • Buiten de zone 2
gebied • Standaardtoepassingen van decentrale
periferie

Hierna vindt u belangrijke aanwijzingen voor de installatie van de componenten van de

buskoppeling DP/DP in een explosief gebied.

Verdere informatie
In het handboek vindt u verdere informatie over de buskoppeling DP/DP en over de
verschillende componenten.

Productieplaats
Siemens AG, Bereich A&D
Werner-von-Siemens-Strasse 50
92224 Amberg
Germany

Vergunning

II 3 G EEx nA II T4 conform EN 50021 : 1999

Keuringsnummer: KEMA 02ATEX1096 X

Opmerking
Modulen met de vergunning II 3 G EEx nA II T4 mogen slechts worden
gebruikt in automatiseringssystemen SIMATIC S5/S7 / DP-slaves van de
apparaatcategorie 3G.

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 Technical Data

Instandhouding
De te herstellen component moet voor reparatie naar de plaats van vervaardiging worden
gestuurd. Alleen daar mag de reparatie worden uitgevoerd.

Speciale voorwaarden
1. De buskoppeling DP/DP moet worden ingebouwd in een schakelkast of in een
behuizing van metaal. Deze moeten minstens de veiligheidsgraad IP 54 waarborgen.
Hierbij dient rekening te worden gehouden met de omgevingsvoorwaarden waarin het
apparaat wordt geïnstalleerd. Voor de behuizing dient een verklaring van de fabrikant
voor zone 2 te worden ingediend (volgens EN 50021).
2. Als aan de kabel of aan de kabelinvoering van deze behuizing onder
bedrijfsomstandigheden een temperatuur wordt bereikt > 70 °C of als onder
bedrijfsomstandigheden de temperatuur aan de adervertakking > 80 °C kan zijn,
moeten de temperatuureigenschappen van de kabel overeenstemmen met de
werkelijk gemeten temperaturen.
3. De aangebrachte kabelinvoeringen moeten de vereiste IP-veiligheidsgraad hebben en
in overeenstemming zijn met alinea 7.2 (volgens EN 50021).
4. Alle apparaten, schakelaars enz. inbegrepen, die worden aangesloten op de in- en
uitgangen van de buskoppeling DP/DP, moeten zijn goedgekeurd voor de
explosiebeveiliging type EEx nA of EEx nC.
5. Er dienen maatregelen te worden getroffen, zodat de nominale spanning door
transiënten met niet meer dan 40 % kan worden overschreden.
6. Omgevingstemperatuurbereik: 0° C tot 60° C
7. Binnen de behuizing dient op een na het openen goed zichtbare plaats een bord te
worden aangebracht met de volgende waarschuwing:
Waarschuwing
De behuizing mag slechts voor korte tijd worden geopend, bijv. voor een visuele
diagnose. Bedien hierbij geen schakelaar, trek of steek geen modulen en ontkoppel
geen elektrische leidingen (steekverbindingen).
Deze waarschuwing kan buiten beschouwing blijven, indien bekend is dat er geen
explosieve atmosfeer heerst.

Lijst van de toegelaten modulen

De lijst met de toegelaten modulen vindt u in het internet:
http://www4.ad.siemens.de/WW/view/en/13702947.

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A.3.7 Brug af DP/DP-kobleren i det eksplosionfarlige område

zone 2

Zone 2
Eksplosionsfarlige områder inddeles i zoner. Zonerne adskiller sig indbyrdes efter hvor
sandsynligt det er, at der er en eksplosiv atmosfære.
Zone Eksplosionsfare Eksempel
2 Eksplosiv gasatmosfære Områder rundt om flangeforbindelser med flade
optræder kun sjældent og varer pakninger ved rørledninger i lukkede rum
kort
Sikkert Nej • Uden for zone 2
område • Standardanvendelser decentral periferi

I det følgende findes vigtige henvisninger vedr. installation af komponenterne til DP/DP-
kobleren i det eksplosionsfarlige område.

Yderligere informationer
Yderligere informationer om DP/DP-kobleren og de forskellige komponenter findes i
manualen.

Produktionssted
Siemens AG, Bereich A&D
Werner-von-Siemens-Straße 50
92224 Amberg
Germany

Godkendelse

II 3 G EEx nA II T4 efter EN 50021 : 1999

Kontrolnummer: KEMA 02ATEX1096 X

Bemærk
Komponenter med godkendelsen II 3 G EEx nA II T4 må kun monteres i
automatiseringssystemer SIMATIC S5/S7 / DP-slaves - udstyrskategori 3G.

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Vedligeholdelse
Skal den pågældende komponent repareres, bedes De sende den til produktionsstedet.
Reparation må kun udføres der.

Særlige betingelser
1. DP/DP-kobleren skal monteres i et kontrolskab eller et metalkabinet. Disse skal
mindst kunne sikre beskyttelsesklasse IP 54. I denne forbindelse skal der tages højde
for de omgivelsestemperaturer, i hvilke udstyret er installeret. Der skal være
udarbejdet en erklæring fra fabrikanten for kabinettet for zone 2 (iht. EN 50021).
2. Hvis kablet eller kabelindføringen på dette hus når op på en temperatur på > 70 °C
under driftsbetingelser eller hvis temperaturen på åreforegreningen kan være > 80 °C
under driftsbetingelser, skal kablernes temperaturegenskaber stemme overens med
de temperaturer, der rent faktisk måles.
3. De benyttede kabelindføringer skal være i overensstemmelse med den krævede IP-
beskyttelsestype og afsnittet 7.2 (iht. EN 50021).
4. Alle apparater, inkl. kontakter osv., der forbindes med ind- og udgangene på DP/DP-
kobleren, skal være godkendt til eksplosionsbeskyttelse af type EEx nA eller EEx nC.
5. Der skal træffes foranstaltninger, der sørger for, at den nominelle spænding via
transienter ikke kan overskrides mere end 40 %.
6. Omgivelsestemperaturområde: 0° C til 60° C
7. I kabinettet skal der anbringes et skilt, der skal kunne ses, når kabinettet åbnes. Dette
skilt skal have følgende advarsel:
Advarsel
Kabinettet må kun åbnes i kort tid, f.eks. til visuel diagnose. Tryk i denne forbindelse
ikke på kontakter, træk eller isæt ikke komponenter og afbryd ikke elektriske ledninger
(stikforbindelser).
Denne advarsel skal der ikke tages højde for, hvis man ved, at der ikke er nogen
eksplosionsfarlig atmosfære.

Liste over godkendte komponenter

Listen med de godkendte komponenter findes på internettet:
http://www4.ad.siemens.de/WW/view/en/13702947.

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A.3.8 Väyläkytkennän DP/PA-kytkimen käyttö

räjähdysvaarannetuilla alueilla, vyöhyke 2

Vyöhyke 2
Räjähdysvaarannetut alueet jaetaan vyöhykkeisiin. Vyöhykkeet erotellaan
räjähdyskelpoisen ilmakehän olemassa olon todennäköisyyden mukaan.
Vyöhyke Räjähdysvaara Esimerkki
2 Räjähtävä kaasuilmakehä Alueet putkistojen lattatiivisteillä varustuilla
ilmaantuu vain harvoin ja laippaliitoksilla suljetuissa tiloissa
lyhytaikaisesti
turvallinen ei • vyöhykkeen 2 ulkopuolella
alue • Hajautetun ulkopiirin vakiosovellukset

Seuraavasta löydätte tärkeitä ohjeita DP/PA-kytkimen asennukseen

räjähdysvaarannetuilla alueilla.

Lisätietoja
Lisätietoja DP/PA-kytkimeen ja erilaisiin komponentteihin löydätte ohjekirjasta.

Valmistuspaikka
Siemens AG, Bereich A&D
Werner-von-Siemens-Straße 50
92224 Amberg
Germany

Hyväksyntä

II 3 G EEx nA II T4 EN 50021 mukaan: 1999

Tarkastusnumero: KEMA 02ATEX1096 X

Ohje
Rakenneryhmät hyväksynnän II 3 G EEx nA II T4 kanssa saadaan käyttää
ainoastaan laitekategorian 3G automatisointijärjestelmissä SIMATIC S5/S7 / DP-
Slaves.

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Kunnossapito
Korjausta varten täytyy kyseinen komponentti lähettää valmistuspaikkaan. Korjaus
voidaan suorittaa ainoastaan siellä.

Erityiset vaatimukset
1. DP/PA-kytkin täytyy asentaa kytkentäkaappiin tai metalliseen koteloon. Näiden täytyy
olla vähintään kotelointiluokan IP 54 mukaisia. Tällöin on huomioitava
ympäristöolosuhteet, johon laite asennetaan. Kotelolle täytyy olla valmistajaselvitys
vyöhykettä 2 varten (EN 50021 mukaan).
2. Kun johdolla tai tämän kotelon johdon sisäänviennillä saavutetaan > 70 °C lämpötila
tai kun käyttöolosuhteissa lämpötila voi piuhajaotuksella olla > 80 °C, täytyy johdon
lämpötilaominaisuuksien vastata todellisesti mitattuja lämpötiloja.
3. Käytettyjen johtojen sisäänohjauksien täytyy olla vaaditun IP-kotelointiluokan ja
kohdan 7.2 (EN 50021 mukaan) mukaisia.
4. Kaikkien laitteiden, kytkimet jne. mukaan lukien, jotka liitetään DP/PA-kytkimen tuloille
ja lähdöille, täytyy olla hyväksyttyjä tyypin EEx nA tai EEx nC räjähdyssuojausta
varten.
5. Toimenpiteet täytyy suorittaa, ettei nimellisjännite voi transienttien kautta ylittyä
enemmän kuin 40 %.
6. Ympäristölämpötila-alue: 0° C ... 60° C
7. Kotelon sisälle, avauksen jälkeen näkyvälle paikalle, on kiinnitettävä kilpi, jossa on
seuraava varoitus:
Varoitus
Kotelo saadaan avata ainoastaan lyhyeksi ajaksi, esim. visuaalista diagnoosia varten.
Älä tällöin käytä mitään kytkimiä, vedä tai liitä mitään rakenneryhmiä, äläkä erota
mitään sähköjohtoja (pistoliittimiä).
Tätä varoitusta ei tarvitse huomioida, kun on tiedossa, että minkäänlaista
räjähdysvaarannettua ilmakehää ei ole olemassa.

Hyväksyttyjen rakenneryhmien lista

Lista hyväksiytyistä rakennesarjoista löytyy internetistä osoitteesta:
http://www4.ad.siemens.de/WW/view/en/13702947.

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A.3.9 Användning av DP/DP-kopplaren i explosionsriskområde

zon 2

Zon 2
Explosionsriskområden delas in i zoner. Zonerna delas in enligt sannolikheten att en
atmosfär med explosionsfara föreligger.
Zon Explosionsfara Exempel
2 Explosiv gasatmosfär uppstår Områden kring flänsförbindelser med packningar
endast sällan eller kortvarigt vid rörledningar i slutna utrymmen
Säkert Nej • Utanför zon 2
område • Standardanvändning av decentral periferi

Nedan följer viktiga anvisningar om installationen av DP/DP-kopplaren i ett

explosionsriskområde.

Ytterligare information
Ytterligare information om DP/DP-kopplaren och de olika komponenterna finner du i
handboken.

Tillverkningsort
Siemens AG, Bereich A&D
Werner-von-Siemens-Straße 50
92224 Amberg
Germany

Godkännande

II 3 G EEx nA II T4 enligt EN 50021 : 1999

Kontrollnummer: KEMA 02ATEX1096 X

Anvisning
Komponentgrupper med godkännande II 3 G EEx nA II T4 får endast
användas i automatiseringssystemen SIMATIC S5/S7 / DP Slaves från
apparatgrupp 3G.

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Underhåll
Vid reparation måste den aktuella komponenten insändas till tillverkaren. Reparationer får
endast genomföras där.

Särskilda villkor
1. DP/DP-kopplaren måste monteras i ett kopplingsskåp eller metallhus. Dessa måste
minst vara av skyddsklass IP 54. Därvid ska omgivningsvillkoren där enheten
installeras beaktas. För kåpan måste en tillverkardeklaration för zon 2 föreligga (enligt
EN 50021).
2. Om en temperatur på > 70°C uppnås vid husets kabel resp kabelinföring under
driftvillkor eller om temperaturen vid trådförgreningen kan vara > 80°C under
driftvillkor, måste kabelns temperaturegenskaper överensstämma med den verkligen
uppmätta temperaturen.
3. De använda kabelinföringarna måste uppfylla kraven i det krävda IP-skyddsutförandet
och i avsnitt 7.2 (enligt EN 50021).
4. Alla apparater, inklusive brytare osv, som ansluts till DP/DP-kopplarens in- och
utgångar, måste vara godkända för explosionsskydd av typ EEx nA eller EEx nC.
5. Åtgärder måste vidtas så, att märkspänningen ej kan överskridas med mer än 40°%
genom transienter.
6. Omgivningstemperatur: 0° C till 60° C
7. När huset öppnats ska en skylt med följande varning monteras på ett tydligt synligt
ställe huset:
Varning
Huset får endast öppnas under kort tid, t ex för visuell diagnos. Använd därvid inga
brytare, lossa eller anslut inga enheter och frånskilj inga elektriska ledningar
(insticksanslutningar).
Ingen hänsyn måste tas till denna varning om det är säkert att det inte råder någon
explosionsfarlig atmosfär.

Lista över godkända komponentgrupper

Lista över godkända enheter återfinns i Internet:
http://www4.ad.siemens.de/WW/view/en/13702947.

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A.3.10 Uso do acoplador DP/DP em área exposta ao perigo de

explosão, zona 2

Zona 2
As áreas expostas ao perigo de explosão são divididas em zonas. As zonas são
diferenciadas de acordo com a probabilidade da existência de uma atmosfera explosiva.
Zona Perigo de explosão Exemplo
2 Só raramente e por um breve Áreas em torno de ligações flangeadas com
período de tempo surgem vedações chatas em tubulações em recintos
atmosferas explosivas fechados
Área segura não • fora da zona 2
• Aplicações descentralizadas de periferia
descentralizada

A seguir, o Sr. encontrará avisos importantes para a instalação do acoplador DP/DP em

área exposta ao perigo de explosão.

Mais informações
Para obter mais informações sobre o acoplador DP/DP e sobre os diversos
componentes, consulte o manual.

Local de produção
Siemens AG, Bereich A&D
Werner-von-Siemens-Straße 50
92224 Amberg
Germany

Licença

II 3 G EEx nA II T4 seg. EN 50021 : 1999

Número de ensaio: KEMA 02ATEX1096 X

Aviso
Componentes com a licença II 3 G EEx nA II T4 só podem ser aplicados em
sistemas de automação SIMATIC S5/S7 / escravos DP da categoria de
aparelho 3G.

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Reparo
Os componentes em questão devem ser remetidos para o local de produção a fim de
que seja realizado o reparo. Apenas lá deve ser efetuado o reparo.

Condições especiais
1. O acoplador DP/DP deve ser montado em um armário de distribuição ou em uma
caixa metálica. Estes devem garantir no mínimo o tipo de proteção IP 54. Durante
este trabalho deverão ser levados em consideração as condições locais, nas quais o
aparelho será instalado. Para a caixa deverá ser apresentada uma declaração do
fabricante para a zona 2 (de acordo com EN 50021).
2. Caso no cabo ou na entrada do cabo desta carcaça sob as condições operacionais
seja atingida uma temperatura de > 70 °C, ou caso sob condições operacionais a
temperatura na ramificação do fio poderá atingir > 80 °C, as caraterísticas de
temperatura deverão corresponder às temperaturas realmente medidas.
3. As entradas de cabo utilizadas devem corresponder ao tipo exigido de proteção IP e à
seção 7.2 (de acordo com o EN 50021).
4. Todos os aparelhos, inclusive as chaves, etc., que estejam conectadas em entradas e
saídas do acoplador DP/DP, devem possuir a licença para a proteção de explosão do
tipo EEx nA ou EEx nC.
5. Precisam ser tomadas medidas para que a tensão nominal através de transitórios não
possa ser ultrapassada em mais que 40 %.
6. Área de temperatura ambiente: 0° C até 60° C
7. No âmbito da carcaça deve ser colocada, após a abertura, em um ponto bem visível
uma placa com a seguinte advertência:
Advertência
A carcaça deve ser aberta apenas por um breve período de tempo, por ex. para
diagnóstico visual. Não acione nenhum interruptor, não retire ou conecte nenhum
módulo e não separe nenhum fio elétrico (ligações de tomada).
Esta advertência poderá ser ignorada caso se saiba que não há nenhuma atmosfera
sujeita ao perigo de explosão.

Lista dos componentes autorizados

A lista com os módulos autorizados encontram-se na Internet:
http://www4.ad.siemens.de/WW/view/en/13702947.

DP/DP Coupler
A5E00224669-03 A-33
Technical Data

A.3.11 Χρήση του συζεύκτη DP/DP σε επικίνδυνη για έκρηξη

περιοχή, ζώνη 2

Ζώνη 2
Οι επικίνδυνες για έκρηξη περιοχές χωρίζονται σε ζώνες. Οι ζώνες διαφέρουν σύµφωνα
µε την πιθανότητα ύπαρξης ενός ικανού για έκρηξη περιβάλλοντος.
Ζώνη Κίνδυνος έκρηξης Παράδειγµα
2 Εκρηκτικό περιβάλλον αερίου Περιοχές γύρω από φλαντζωτές συνδέσεις µε
παρουσιάζεται µόνο σπάνια και τσιµούχες σε σωληνώσεις σε κλειστούς χώρους
για σύντοµο χρονικό διάστηµα
Ασφαλής όχι • Εκτός της ζώνης 2
περιοχή • Τυπικές εφαρµογές αποκεντρωµένης
περιφέρειας

Στη συνέχεια θα βρείτε σηµαντικές υποδείξεις για την εγκατάσταση του συζεύκτη DP/DP
σε επικίνδυνη για έκρηξη περιοχή.

Επιπλέον πληροφορίες
Επιπλέον πληροφορίες για το συζεύκτη DP/DP και για τα διάφορα εξαρτήµατα θα βρείτε
στο εγχειρίδιο.

Τόπος κατασκευής
Siemens AG, Bereich A&D
Werner-von-Siemens-Straße 50
92224 Amberg
Germany

Άδεια

II 3 G EEx nA II T4 σύµφωνα µε το πρότυπο EN 50021 : 1999

Αριθµός ελέγχου: KEMA 02ATEX1096 X

Υπόδειξη
Τα δοµικά συγκροτήµατα µε την άδεια II 3 G EEx nA II T4 επιτρέπεται να
τοποθετηθούν µόνο σε συστήµατα αυτοµατισµού SIMATIC S5/S7 / DP-Slaves της
κατηγορίας συσκευής 3G.

DP/DP Coupler
A-34 A5E00224669-03
 Technical Data

Συντήρηση
Για µια επισκευή πρέπει να σταλθεί το αντίστοιχο εξάρτηµα στον τόπο κατασκευής. Μόνο
εκεί επιτρέπεται να γίνει η επισκευή.

Ιδιαίτερες προϋποθέσεις
1. Ο συζεύκτης DP/DP πρέπει να ενσωµατωθεί σε ένα ερµάριο ζεύξης ή σε ένα
µεταλλικό περίβληµα. Αυτά πρέπει να εξασφαλίζουν το λιγότερο το βαθµό προστασίας
IP 54. Σε αυτήν την περίπτωση πρέπει να ληφθούν υπόψη οι περιβαλλοντικές
συνθήκες, στις οποίες θα εγκατασταθεί η συσκευή. Για το περίβληµα πρέπει να
προβλέπεται δήλωση του κατασκευαστή για τη ζώνη 2 (σύµφωνα µε το πρότυπο
EN 50021).
2. Εάν στο καλώδιο ή στην είσοδο του καλωδίου αυτού του περιβλήµατος κάτω από
συνθήκες λειτουργίας η θερµοκρασία ξεπεράσει τους 70 °C ή όταν κάτω από
συνθήκες λειτουργίας η θερµοκρασία στη διακλάδωση του σύρµατος µπορεί να είναι
µεγαλύτερη από 80 °C, πρέπει οι θερµοκρασιακές ιδιότητες των καλωδίων να
ταυτίζονται µε τις πραγµατικά µετρηµένες θερµοκρασίες.
3. Οι χρησιµοποιούµενες εισόδοι καλωδίων πρέπει να συµµορφώνονται µε το βαθµό
προστασίας IP 54 στην ενότητα 7.2 (σύµφωνα µε το πρότυπο EN 50021).
4. Όλες οι συσκευές, συµπεριλαµβανοµένων διακοπτών κ.α., που συνδέονται στις
εισόδους και εξόδους του συζεύκτη DP/DP, πρέπει να φέρουν εγκριµένη προστασία
κατά έκρηξης τύπου EEx nA ή EEx nC.
5. Πρέπει να ληφθούν µέτρα, να µην µπορεί να γίνει υπέρβαση της ονοµαστικής τάσης
µέσω αιφνίδιας µεταβολής της τάσης πάνω από 40 %.
6. Περιοχή θερµοκρασίας περιβάλλοντος: 0° C έως 60° C
7. Πρέπει να τοποθετηθεί µέσα στο περίβληµα σε ευδιάκριτο σηµείο µετά το άνοιγµα µία
πινακίδα µε την ακόλουθη προειδοποίηση:
Προειδοποίηση
Το περίβληµα επιτρέπεται να ανοίγει µόνο για µικρό χρονικό διάστηµα, π.χ. για τη
διενέργεια οπτικής διάγνωσης. Μην κάνετε χρήση διακοπτών, µην τραβάτε ή
εµβυσµατώνετε δοµικά συγκροτήµατα και µη διαχωρίζετε ηλεκτροφόρους αγωγούς
(εµβσυµατώσιµες συνδέσεις).
Η προειδοποίηση αυτή δε χρειάζεται να ληφθεί υπ’ όψιν, εάν είναι γνωστό ότι δεν
υφίσταται ατµόσφαιρα παρουσιάζουσα κίνδυνο έκρηξης.

Κατάλογος των εγκεκριµένων δοµικών συγκροτηµάτων

Η λίστα µε τα εγκριµένα δοµικά συγκροτήµατα υπάρχει στο διαδίκτυο:
http://www4.ad.siemens.de/WW/view/en/13702947.

DP/DP Coupler
A5E00224669-03 A-35
Technical Data

DP/DP Coupler
A-36 A5E00224669-03
Order numbers and accessories B
Table B-1 Order numbers for the DP/DP Coupler

Component Order number

DP/DP Coupler 6ES7 158-0AD01-0XA0
DIN rail 35 mm
• 483 mm 6ES5 710-8MA11
• 530 mm 6ES5 710-8MA21
• 830 mm 6ES5 710-8MA31
• 2000 mm 6ES5 710-8MA41
Rail for the S7 mounting system
• 482 mm 6ES7 390-1AE80-0AA0
• 530 mm 6ES7 390-1AF30-0AA0
• 830 mm 6ES7 390-1AJ30-0AA0
• 2000 mm 6ES7 390-1BC00-0AA0
Bus connector for PROFIBUS DP
• for looping the PROFIBUS DP 6ES7 972-0BA12-0XA0
(without PG socket) 6ES7 972-0BA50-0XA0 (FastConnect)
• for looping the PROFIBUS DP 6ES7 972-0BB12-0XA0
(with PG socket) 6ES7 972-0BB50-0XA0 (Fast Connect)
PROFIBUS DP bus cable
• Normal (flexible) 6XV1 830-0EH10

DP/DP Coupler
A5E00244669-03 B-1
Order numbers and accessories

DP/DP Coupler
B-2 A5E00244669-03
Glossary

Address
The address of a node is used to identify it on the network. It must be unique
throughout the entire system.

Equipment, electrical
Components, electrical circuits or parts of electrical circuits which are usually
contained in a single enclosure.

Bus
Shared data transfer path to which all nodes are connected; with two defined end
points.

Bus connector
Physical connection between the bus node and the bus cable.

Chassis ground
Chassis ground is formed by the interconnection of inactive equipment parts,
which can not acquire any hazardous contact voltage in the event of a
malfunction.

Diagnostics
Diagnostics is the detection, localization, classification, indication and analysis of
errors, faults and messages.
The diagnostics system provides automatic monitoring functions for system
runtime. This increases the availability of systems by reducing startup times and
downtimes.

DP master
A ³ master that responds in accordance with IEC 61784-1:2002 Ed1 CP 3/1 is
referred to as a DP master.

DP/DP Coupler
A5E00244669-03 Glossary-1
Glossary

DP standard
Represents the bus protocol of the DP system in accordance with
IEC 61784-1:2002 Ed1 CP 3/1.

DP slave
This ³ slave type is operated on PROFIBUS based on the PROFIBUS DP
protocol, and responds in accordance with IEC 61784-1:2002 Ed1 CP 3/1.

Earth
Conductive earth, the electrical potential of which can be set equal to zero at any
point.

Electromagnetic Compatibility (EMC)

Electromagnetic compatibility is the capability of electrical equipment to work free
of problems in a defined environment without affecting its environment in an
impermissible manner.

Equipotential bonding
An electrical connection (equipotential conductor) that keeps the body of
electrical equipment and external conductive bodies at the same or close to the
same potential, in order to prevent the development of interference or hazardous
voltages between these bodies.

Grounding
Grounding means connecting an electrically conductive component to ground by
means of a grounding system.

GSD file
All slave-specific characteristics are stored in a GSD file. The format of the GSD
file is defined in the PROFIBUS Guideline: Specification for PROFIBUS Device
Description and Device Integration Vol.1: GSD V4.1, 07/2001 of the
PROFIBUS User Organisation (PUO).

HW Config
Hardware configuration component in STEP 7.

DP/DP Coupler
Glossary-2 A5E00244669-03
 Glossary

Master
Masters in possession of the token may transmit data to other nodes, and
request data from other nodes (= active node). The CPU 315-2 DP or IM 308-C
are Dp masters, for example.

Parameter assignment
Parameter assignment is the passing of slave parameters from the master to the
slave.

Power supply unit

This unit supplies power to the field devices and their process peripherals.

PROFIBUS
Process field bus standard that is defined in the field bus standard to
IEC 61784-1:2002 Ed1 CPF 3 PROFIBUS and PROFInet. It defines functional,
electrical and mechanical properties for a bit-serial field bus system.
PROFIBUS is available with the following protocols: DP (for distributed
I/O systems) and FMS (= Fieldbus Message Specification).

PROFIBUS address
Each bus node must be assigned a PROFIBUS address that uniquely identifies it
on the PROFIBUS-DP.
The PC / PG or hand-held ET200 are assigned the PROFIBUS address “0”.
The PROFIBUS address of the DP masters and DP slaves lie within the range
from 1 to 125.

PROFIBUS DP
This is the PROFIBUS system based on the DP protocol. The abbreviation DP
stands for Distributed Peripherals.

PUO
PROFIBUS user organization

Reference potential
Electrical potential that forms the reference for viewing and/or measuring the
voltage of relevant circuits.

DP/DP Coupler
A5E00244669-03 Glossary-3
Glossary

SELV
Safety extra-low voltage (SELV) is a voltage of vv 30 V AC / 60 V DC
generated by means of a safety isolating transformer, battery, etc.

TN-S system
In a TN-S system, the neutral conductor (N) and protective conductor (PE) are
routed separately. The neutral conductor is always connected to the grounded
protective conductor at a central point. The conductor can be grounded any
number of times.

Terminating resistor
Terminating resistors are used to terminate the data transmission line in order to
avoid reflections.

Transmission rate
The transmission rate defines the number of transmitted bits per second.

Ungrounded
without galvanic connection to earth

DP/DP Coupler
Glossary-4 A5E00244669-03
Index
A D
Accessories, B-1 Data validity indication, 4-4
ADDR, 4-5 Device identifier, 6-8
Address, Glossary-1 DIA, 4-4
Ambient conditions Diagnostics, Glossary-1, Glossary-2,
mechanical, A-9 Glossary-4
operation, A-9 by means of LED indication, 6-2
transport and storage, A-8 by means of the user program, 6-4
Appearance, 1-3 Example, 6-11
Approbation, iv DIN rail, 2-2
Approvals, A-2 Display elements, 1-3, 6-2
Australia – Label, A-3 DP master, Glossary-1
DP slave, Glossary-2
DP Standard, Glossary-2
B DP/DP Coupler
installation , 2-2
Basic knowledge, iii
Technical data, A-12
BF, 6-2
DPV0 / DPV1, 4-11
Bus, Glossary-1
DPV1, iii
Bus connector, Glossary-1
Dual power supply, 3-7
dual power supply, iii
C
C–Tick, iv E
CE, certification, A-2
Electrical isolation, 3-1
CE label, iv
Electromagnetic compatibility, A-6
Certification, CE, A-2
EMERGENCY–OFF equipment, 3-2
Changes compared with the previous version,
Enhancements, iii
iii
Equipment
Chassis ground, Glossary-1
electrical, Glossary-1
Climatic ambient conditions, A-10
open, 2-1
climatic, A-10
Equipotential bonding, Glossary-2
Commissioning, 4-1, 4-14
Error indication, 6-2
Compatibility, 1-4
External diagnostics, 4-11
Components, 2-2
Configuration, 1-1
Procedure, 4-2
Configuration frame, 4-13 F
Configuration in STEP 7, Example, 4-12 Field of application, 1-1
Configuring in STEP 7, 4-8 FM approval, A-3
Configuring using another engineering tool, Function, 1-1
4-13 Further support, v
Connections, 3-6
CSA approval, A-3

DP/DP Coupler
A5E00244669-03 Index-1
Index

G P
Galvanic properties, 3-1 Parameter assignment, 1-1, Glossary-3
Grounding, 3-1, Glossary-2 Parameter assignment frame, 4-13
GSD file, 4-8, 4-13, Glossary-2 Potentially explosive environments, A-13
Power supply
connection, 3-7
H dual, iii, 3-7
Power supply unit, Glossary-3
Hotline, v
Procedure, Configuration, 4-2
HW Config, Glossary-2
PROFIBUS, Glossary-3
PROFIBUS address, Glossary-3
PROFIBUS address of the DP master, 6-8
I PROFIBUS cable, 3-4
IEC 61131, A-4 PROFIBUS DP, Glossary-3
Industrial area, use in the, A-4 connecting, 3-8
Information landscape, iv PROFIBUS standard, A-4
Installation, 2-2 Profile rail for the S7 installation system, 2-3
Insulation test, A-11 Programming, 1-1
Interference Programming example, 1-2
pulse-type, A-6 Properties, 1-3
sinusoidal, A-7 Properties – DP slave, 4-11
Internet address, v Protection class, A-11
Protection type, A-11
PS, 4-3
L PUO, Glossary-3
LED indication, 6-2
LEDs, 6-2
R
Radio interference, emission of, A-7
M Range of validity, iii
Rated voltage, A-11
Manual guide, v
Recycling, v
Manual objectives, iii
Reference potential, Glossary-3
Manuals, Further important manuals, iv
grounded, 3-5
Master, Glossary-3
Removal, 2-3
Module diagnostics
Replacement of a faulty DP/DP Coupler, 5-1
in replacement part mode, 6-10
Residential areas, use in, A-5
status message, 6-8
Response times, 5-2
Module replacement, 5-1
Mounting position, 2-1
Mounting system, 2-1
S
SELV, Glossary-4
N Service, vii
Setting the DIL switch, 4-3
Newsletter, vii
Setting the PROFIBUS address, iii, 4-6, 4-10
SF, 6-2
Slave diagnosis, 6-4
O Standard diagnosis, 6-6
Objectives of this manual, iii Standards, iv, A-2
ON, 6-2 Station status, 6-6
Operating conditions, A-9 Status indication, 6-2
Operator elements, 1-3 Status message, Module diagnostics, 6-8
Order numbers, B-1

DP/DP Coupler
Index-2 A5E00244669-03
 Index

STEP 7, Setting the properties of the DP/DP U

Coupler, 4-11
UL approvals, A-3
Support on the Internet, vii
Ungrounded installation , 3-2
Use, in potentially explosive environments,
A-13
T
Technical data, A-1
Terminating resistor, Glossary-4 V
Test voltages, A-11
Vibrations, A-9
TN-S system, Glossary-4
Training Center, v
Transmission rate, Glossary-4

DP/DP Coupler
A5E00244669-03 Index-3
Index

DP/DP Coupler
Index-4 A5E00244669-03