Sinamics G120

Multimedia Training Package

www.siemens.com/sinamics-g120

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 Required System Configuration CD-ROM
• Processor with min. 2 GHz (dual core recommended)
• 1024 MB RAM
• Graphics card (min. 256 MB memory recommended)
• Screen resolution: 1280 x 1024 px
• Operating Systems:
Microsoft® Windows™ XP (Service Pack 2 or later)
Microsoft® Windows™ Vista
Microsoft® Windows™ 7

I_DT_G120_Booklet_RZ.indd 2 04.04.2012 13:11:27

 SINAMICS G120
Training Booklet

This booklet contains the same information as the attached CD. Still, we highly recommend to work through the learn-
ing program before consulting the booklet. The multimedia tutorial is a comfortable and easy to understand introduc-
tion to the converter family SINAMICS G120.
04/2012
6FC5095-0AA85-0BA0

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 Materials and tools
The components listed below are presented in this booklet. To test your knowledge on the actual
­ roduct, you have the choice between the following order alternatives:
p

Training case

Product Order no.

• SINAMICS G120 training case* 6ZB2480-0CJ00

Single components

Product Order no.

• SINAMICS G120 PM240-2 FSA 0.55kW 6SL3210-1PE11-8AL0
• SINAMICS G120 CU240E-2 6SL3244-0BB12-1BA1
• Motor (0.55 kW) 1LA7096-4AA10
• SINAMICS PC Connection Kit-2 6SL3255-0AA00-2CA0
• SINAMICS BOP-2 6SL3255-0AA00-4CA1
• Intelligent Operator Panel IOP 6SL3255-0AA00-4JA0
• Screening kit 2 6SL3264-1EA00-0HA0

Optional components

Product Order no.

• IOP/BOP-2 door mounting kit 6SL3256-0AP00-0JA0

In addition, you will need the following equipment:

• PC with USB interface
• Switches – commercially available*
• Potentiometer – commercially available*
• Various M4 screws and nuts (length depends on installation location) with suitable screwdriver/
wrench – commercially available*
*T
 he training case is a complete demo station including a motor, the power module of the converter, switches, lights and
a 230 V power supply connection.

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 Safety instructions

Validity

These instructions apply to the following converter:

Product
SINAMICS G120

Prerequisites

You are proficient in working with the Microsoft® Windows™ operating system.
You are conversant with the principles of electronics and electrical engineering.

Warning

Dangerous currents and voltages!

The equipment contains dangerous voltages and controls potentially dangerous rotating mechanical
parts. Non-compliance with the warnings or failure to follow the instructions contained in the docu-
mentation can result in loss of life, severe personal injury or serious damage to property.
Take particular notice of the general and regional installation and safety regulations regarding work
on dangerous voltage installations (e.g. EN 50178) as well as the relevant regulations regarding the
correct use of tools and personal protective equipment (PPE).

Qualified Personnel

The device/system may only be set up and used in conjunction with this documentation. Commission-
ing and operation of a device/system may only be performed by qualified personnel. Within the con-
text 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 estab-
lished safety practices and standards.

Disclaimer of Liability

Depending upon the firmware and software version of the Control Unit, of the Operator Panel and of
the STARTER, the masks, symbols and menus may differ. We have reviewed the contents of this publi-
cation 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 publica-
tion is reviewed regularly and any necessary corrections are included in subsequent editions.

I_DT_G120_Booklet_RZ.indd 5 04.04.2012 13:11:28

 Welcome to the SINAMICS G120 Tutorial for First Time
Users. This tutorial will help acquaint you simply, quick-
ly and comfortably with the frequency converter. We’ll
take you step by step through installation, setting
­parameters and initial start-up. We recommend that you
don’t skip any chapters.

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1 04.04.2012 13:11:28
 Converter family SINAMICS G120 08–21
1.1 Components Power Module 12
Control Unit 13
Operator Panel 2 (BOP-2/IOP) 14

1.2 Mounting and wiring Power Module 15

Control Unit 18
Operator Panels (BOP-2/IOP) 20
Operator Panels BOP-2 and IOP 22‒41
2.1 Basic functions The BOP-2 display 24
Menu structure 25

2.2 Working with BOP-2 Parameter list  27

Operating pattern 27
Function buttons 29

2.3 Quick commissioning Resetting the converter 30

Setting the control mode 31
Selecting line frequency 31
Entering motor data 32
Specifying application parameters 33
Saving and restoring data 35

2.4 Intelligent Operator Panel The device 37

Working with IOP 38
STARTER software and PC 42‒73
3.1 Mounting and preparation Creating a STARTER project 46
STARTER user interface 49
Loading converter data 50

3.2 Parameterization Configuration wizard 54

Safety Integrated 58
Start motor data identification 62

3.3 Application cases Setting setpoint specifications 65

Saving data 67
Restoring factory settings 70

Appendix Download overview 75

7

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 This chapter will introduce the low-voltage SINAMICS
G120 converter. You’ll learn about the main compo-
nents, hear about its structure and get some practice-
oriented insight about the assembly and wiring of the
frequency converter.

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 Converter family

SINAMICS G120

I_DT_G120_Booklet_RZ.indd 9 04.04.2012 13:11:34

 1.1 Components
The SINAMICS G120 frequency converter is modular.
It comprises of three basic components:

1 The Power Module supplies

voltage to the motor 2 The Control Unit controls and
monitors the Power Module

10 Converter family SINAMICS G120:   Components

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 The Basic Operator Panel (BOP-2) and The optional PC Connection Kit-2

3 the Intelligent Operator Panel (IOP)

are used to operate and monitor the
converter
+ can also be used to set parameters,
operate and monitor the converter;
the kit is required in order to establish
communication between a PC and the
Control Unit

Each Control Unit can be freely

combined with each Power
Module.

nOTE 11

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 Power Module
The device is available in several sizes. Its power range is between 0.37 kW and 250 kW.
The picture shows the PM240-2 frame size A.

1 Rating plate
2 Power connectors
3 Connectors / Braking resistor
1
4 Motor connectors
5 PE terminals

2 5

3 4
3

5 4

Please check the rating plate

to make sure that the module
also meets your requirement
specifications.

Note
12 Converter family SINAMICS G120:   Components

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 Control Unit
There are various designs for the Control Units. They differ primarily in terms of the control terminal
assignments as well as in terms of different field bus interfaces. This tutorial will use the example of the
CU240E-2 Control Unit. It was developed for stand-alone operation.

8
1 Rating plate
2 DIP switch for analog inputs
7
and fieldbus address
3
3 Interface for the Operator
Panel (BOP-2 or IOP)
4 Status LEDs
5 Terminals for digital and
1
­analog inputs and outputs
6 USB interface for STARTER
7 Interface to the Power
Module
6
2 8 Fastening clips
4

8
5

An overview of the various control

unit versions and their differentia-
tion can be found in the official
SINAMICS G120 brochure at:
http://www.siemens.com/
sinamics-g120/printmaterial

Note 13

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 Basic Operator Panel 2 (BOP-2)
The basic input and display device is used to operate and set parameters for the converter after being
connected to the Control Unit. It is operated by pressing the buttons and features a simple commission-
ing thanks to the menu prompting and the 2-line display.
Intelligent Operator Panel
The Intelligent Operator Panel manages the same functions as the BOP-2 but adds several more options.
The integrated application wizard, full graphical diagnostic overviews and plain text increase usability
substantially. It is available in various versions and can be used drive-externally for series commissioning
and on-site diagnosis.

5 5
2
6 1
6

2
4
1

3
BOP-2 IOP
1 Seven operating buttons 1 Graphical display
2 Display 2 Navigation wheel
3 Release catch 3 Five operating buttons
4 Door mounting screw recess 4 USB connection
5 RS232 connector 5 RS232 connector
6 Product rating label 6 Product rating label

14 Converter family SINAMICS G120:   Components

I_DT_G120_Booklet_RZ.indd 14 04.04.2012 13:11:49

 1.2 Mounting and wiring
Before starting assembly, check to ensure the following conditions have been met:
• All required components, tools and small parts have been prepared
• All required cables and lines have been laid in accordance with specifications
• All minimum clearances are being observed

The 5 Safety Regulations must be strictly observed

• Disconnect
• Secure against unintentional restart
• Verify that it is free of voltage
• Ground and bypass
• Cover and shield any adjacent live parts

Mounting of the Power Module into the switch cabinet

Please refer to the drilling pattern accompanying the Power Module for
36.5 mm (1.44") the correct drilling centers and clearance distances above and below the
5.35 mm (0.21")

Power Module.

Example of
186 mm (7.32")

drilling pattern

Normally the motor and converter

are selected in such a way that
they match each other. This is also
the case in our example. However,
the data from the rating plate of
the motor are important for the
62.3mm (2.45") initial start-up of the converter.

Note 15

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 Connecting the Power Module to the motor
Depending on the operating environment, different cable length limits are required for the connection
between the Power Module and motor. Unshielded cables up to 100 m in length are possible in indus-
trial electrical networks.

Wiring the Power Module

1 • Connect the phases and the earth conductor to the terminals U2, V2, W2 and PE

Wiring the motor

2 • Unscrew the cover to the terminal box on the motor (the inside cover of Siemens’ motors
illustrates the possible wiring for the Star connection and the Delta connection)
• Remove the bridge rails from the connecting block and loosen the screws
• Place the bridge rails on the terminal block and screw them into place (depending on the
type of connections required – Star or Delta, in this example a Star connection is shown)
• Insert the cables from the Power Module through the opening of the terminal box to the motor
• Connect the PE connection first
• Slide the phases in accordance to the phase assignment in the connections
• Replace the terminal cover and ensure it is secured with the four screws to the required torque

The motor and Power Module are now connected.

Wiring the power supply

3 • Connect the phases and the earth conductor to the pluggable terminal clamps L1, L2, L3 and PE

The electrical wiring is now complete.

16 Converter family SINAMICS G120:   Mounting and wiring

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 3

Motor lines represent interfering

transmitters. As a result, you
should use shielded cable in order
to meet the corresponding elec-
tromagnetic compatibility condi-
tions. The cable lengths that are
actually possible depend upon the
following:
‒ Operating environment
2 ‒ Converter being used
‒ Reactors and filters used
‒ Shielded or unshielded cable
In order to meet Class A electro-
magnetic compatibility require-
2
ments, you need a filter and a
shielded cable (max. length: 25
meters).

The depicted example shows a

Star connection. The rating plate
provides information about the
correct circuit data: e.g. 230/400 V
∆/Y means that you are connec-
ting the motor in Y with a 400 V
network.

Note 17

I_DT_G120_Booklet_RZ.indd 17 04.04.2012 13:11:54

 Attaching the Control Unit
Connect the Control Unit with the fastening clips on the bottom of the Power Module and then press
the upper edge of the Control Unit against the Power Module until the locking device snaps into place.
Before wiring the control terminals, the terminal cover has to be opened.

General procedure for wiring with the cage clamp mechanism

• Slide the wire into the terminal opening

• The inner clamp opens slightly and snaps the wire tightly into place
The wire is now firmly attached.
• To release the wire press a screw driver onto the lever
• Remove the wire
• Withdraw the screwdriver from the terminal

Wiring the control terminals in the CU240E-2

1 The potentiometer:
• Attach the positive pole of the supply voltage to 1
• Attach the negative pole to 2
• Wire the output of the potentiometer arm to 3
• Close the circuit by connecting 4 with negative pole 2
2 On/Off, Reverse, and Reset buttons:
• Wire the button’s power supply to 9
• Attach the associated digital inputs to terminals 5, 6 and 7
• To close the circuit, connect 28 and 69 to 34
3 Indicator lamps:
• Connect 9 with 20 and 21 to attach the power supply for the LEDs
• Wire the Faults LED to digital output 19 and the Warning LED to digital output 22
• Connect the negative pole to terminal 28
4 Display for frequency output:
• Connect the positive pole to 12
• Connect the negative pole to 13

The wiring is now complete.

18 Converter family SINAMICS G120:   Mounting and wiring

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 4

19

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 Mounting the Operator Panels (BOP-2 or IOP)

• Remove the cover of the RS232 connection by lifting it up and sliding it to the side
1 • Place the bottom edge of the IOP/BOP-2 into the lower recess of the Control Unit housing
2 • Push the IOP/BOP-2 toward the Control Unit until the release-catch clicks into place

20 Converter family SINAMICS G120:   Mounting and wiring

I_DT_G120_Booklet_RZ.indd 20 04.04.2012 13:12:02

 Mounting the IOP or BOP-2 in a cabinet door
The operator panels can simply be mounted in a control cabinet door with just a few manual operations
using the optionally available door mounting kit. Degree of protection IP55 / UL type 12 is achieved
when mounting them in the control cabinet door.

3
4 2

1 Door panel

2 Seal

3 Door mounting bracket

5 4 Screws
5 D-type retaining screws

Mounting the IOP

Identical mounting with BOP-2

Congratulations! Your converter is now ready for operation.

After assembly is completed, the converter’s parameters must be set up, i.e., you must give the
­converter the specific characteristics of the attached motor.

21

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 In this section, you will learn more about the usage of
Operator Panels to control the converter locally on-site.
You’ll learn how to use the Basic Operator Panel 2 (­ BOP-2)
to set up parameters for the converter and the attached
motor and how to operate the converter with the BOP-2.
Then, you will learn how to use the Intelligent Operator
Panel (IOP) to your advantage.

22

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 Basic Operator Panel (BOP-2)
Intelligent Operator Panel (IOP)
23

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 2.1 Basic functions
The Operator Panel is the input and display instrument for controlling the converter. It is used in stand-
alone operation, i.e., locally, on the device, integrated in the cabinet door or as handheld version for
series setup (IOP).

The BOP-2 display

The BOP-2 is used to commission, diagnose (troubleshoot) and display the status of the converter. Up to
2 status values can be simultaneously and continuously monitored. It features a simple navigation using
a transparent and well-structured menu and clearly assigned operator keys.

1 Menu bar indicates the

selected menu function
(see page 25)
1 2
2 Provides information about
3 the selected functionality or
displays the actual value
3 Displays the values

In this tutorial, we introduce an

application that is based on “V/f
control with linear characteristic
curve”. This control method is
typically applied for conveyor
belt applications. We recom-
mend that you work through the
example we have presented here
in order to familiarize yourself
with setting up parameters for a
converter.

Note
24 Operator Panels BOP-2 and IOP:   Basic functions

I_DT_G120_Booklet_RZ.indd 24 04.04.2012 13:12:12

 Menu structure
When moving the menu bar to the following menu function, the following applies:

1 2 3
1 MONITORING

The actual status of the converter/motor system is dis-

played

2 CONTROL 4 5 6

Setpoint, Jog and Reverse mode can be activated

3 DIAGNOSTICS

Faults and alarms can be acknowledged, history and

status is displayed

4 PARAMETER

Parameter values can be viewed and changed

5 SETUP

Basic commissioning of the converter can be per-

formed

6 EXTRAS

Additional functions such as saving and copying data

sets into and from the BOP-2 can be performed

25

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 2.2 Working with BOP-2
The BOP-2 has got seven buttons. For setup and parameterization only the UP and DOWN, OK and ESC
buttons are relevant. The ON, OFF and HAND/AUTO keys are needed for local operation.

1 ESC key – Takes you back to the

­previous screen

2 Up key – Change selection

3 Down key – Change selection

4 OK key – Confirm the selection
5 OFF key – Stops the motor in manual
2 mode

6 HAND / AUTO key – Switches the

c­ ommand source between HAND and
AUTO mode
1 4 7 ON / RUN key – Starts the Motor in
3 manual mode

5 6 7

26 Operator Panels BOP-2 and IOP:   Working with BOP-2

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 Parameter list
To better understand the functionality of the buttons, you should be acquainted with the operating
­pattern: The Basic Operator Panel gives you access to a parameter list. Stored behind the parameters are
parameter values that control the operation of the motor. However, not all the numbers are assigned.

Operating pattern

• Press ESC to enter the menu selection

• Use the UP and DOWN buttons to move the menu bar to PARAMS and press OK
• Press OK to select the Standard Level
Example

ESC OK

The first parameter number that appears is displayed on the left side of the screen: r2 (r stands for read
only and means that you can only read this value but cannot change it). On the right side, the parame-
ter value of the selected number is shown.

• Press UP to access the next parameter

• In this case, P3 appears (P means that you can change the value of this parameter)
• Press OK to edit the parameter
• Use the UP and DOWN buttons to adjust the value
• Confirm the value by pressing OK

ESC OK
Example

OK OK

If you want to change any param-

eter using the parameter list, you
are requested to choose a filter
level (Standard or Expert). The
Standard Level limits the avail-
able parameters, thus limiting
the risk of dangerous parameters.
The Expert Level gives access to
all parameters.

Note 27

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 Some parameters store more than one value. In this case, pressing OK does not take you directly to the
value, but to an index that is displayed in brackets [00] above the actual value.

Example for index parameters

• Pressing OK takes you to [00]

• UP takes you to [01], DOWN back to [00]
• Decide for an index number of your choice
• Press OK again to edit the index
• The value starts flashing
• Adjust the value by pressing UP and DOWN
• Confirm by pressing OK
Example

OK OK OK

A complete list of all parameters

can be found in the “Parameter
Manual: Control Units –
CU240E/B-2” as a download at:
http://support.automation.­
siemens.com/WW/view/
en/49946755

If you want to adjust any blink-

ing/active value digit by digit
(using the UP and DOWN button
might just take too long), you
can always press the OK button
longer than two seconds. After
releasing the button, you can
change any single digit by using
the buttons OK (move to next
digit), ESC (move to previous
digit), UP (increase value), and
DOWN (decrease value).

Note
28 Operator Panels BOP-2 and IOP:   Working with BOP-2

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 Function buttons

With the function buttons, you can actually operate the motor. The HAND/AUTO button changes the
command source between the BOP-2 (HAND) and field bus (AUTO). A hand icon appears in the screen
to indicate HAND mode is active.
• In HAND mode the ON and OFF buttons are enabled
• In AUTO mode the ON and OFF buttons are disabled
• If HAND mode is active, pressing the HAND/AUTO button will switch the converter to AUTO mode
• If AUTO mode is active, pressing the HAND/AUTO button will switch the converter to HAND mode
• Changing HAND to AUTO mode is possible while the motor is still running

Screen Icons

The BOP-2 displays a number of icons at the left-hand side of the display to indicate the actual state
of the converter.
• Command source auto / hand

• Converter status running

• JOG JOG

• Fault / Alarms active

A detailed list of the Fault and

Alarm messages can be found in
the “Parameter Manual: Control
Units – CU240E/B-2” as a down-
load at: http://support.
automation.siemens.com/WW/
view/en/49946755

Note 29

I_DT_G120_Booklet_RZ.indd 29 04.04.2012 13:12:13

 2.3 Quick commissioning
The following descriptions show how to set up the drive using the quick commissioning wizard
­integrated in the BOP-2.

Starting quick commissioning

• Press ESC to enter the menu selection

• Use UP and DOWN to move the menu bar to SETUP and press OK
• The screen will automatically display the next parameter in the commissioning sequence

ESC OK

Quick commissioning begins now. It will help you set all relevant parameters step by step. Parameters
that are not relevant will be skipped automatically. Thus, you adjust the factory settings of your con-
verter to the requirements of your motor.

Resetting the converter

• Press OK while the BOP-2 shows RESET

• Press UP or DOWN to change the value to YES
• Press OK and wait until the BUSY sign disappears
• Now all values are reset to the factory setting

OK OK

Any step of the commissioning

wizard can be skipped by press-
ing the DOWN button. Going
back one step can be done by
pressing the UP button. By con-
firming one step with OK, the
screen will automatically display
the next parameter in the com-
missioning sequence.

Note
30 Operator Panels BOP-2 and IOP:   Quick commissioning

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 Setting the control mode (P1300)

In our example it is assumed that your converter and the motor are new. As a result, a series of
­pre­paratory steps are required, e.g. selecting the control mode. This is indicated by the parameter
­ umber 1300. ‘V/f control with linear characteristic curve’ is defined by the factory setting.
n
• Press OK to modify the parameter value CTRL MOD
• The upper row shows the control mode associated to the actual parameter value below
• Choose your desired control mode value by pressing UP or DOWN
• See how the control mode name in the upper row changes accordingly
• Press OK if the desired control mode is displayed

OK OK

Selecting line frequency (P100)

The next parameter sequence sets the line frequency of the region in which the motor is being used.
In our example, this is Europe.
• Press OK to modify the parameter value EUR USA
• Set 0 for Europe (50 Hz) (1 represents the US line frequency of 60 Hz)
• Confirm the value by pressing OK
• The screen will automatically display the next parameter in the commissioning sequence

OK OK

The applicable line frequency

can be also found on your motor
plate (see chapter “Entering
motor data”).

Note 31

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 Entering motor data

In the next step, the converter is adjusted to the motor. The motor data can be found on the motor’s
rating plate. Please set the values according to the plate.
• Press OK to edit the motor voltage stored under P304
• The preset motor voltage of 400 volts is displayed
• Leave the value and confirm by pressing OK

OK OK OK

1 P304 = MOT VOLT = Motor voltage

D-91056 Erlangen
2 P100 = EUR USA = Standard IEC or NEMA
3~Mot. 1LE10011AC434AA0 E0807/0496382_02 003
IEC/EN 60034 100L IMB3 IP55 3 P305 = MOT CURR = Motor rated current
25 kg Th.Cl. 155(F) -20°C Tamb 40°C
4 P307 = MOT POW = Motor rated power
Bearing UNIREX-N3
DE 6206-2ZC3 15g Intervall: 4000hrs 5 P311 = MOT RPM = Motor rated speed
NE 6206-2ZC3 11g
60Hz: SF 1.15 CONT NEMA MG1-12 TEFC Design A 2.0 HP The line frequency has been set already
V Hz A kW PF NOM.EFF rpm V A CL in the beginning of quick commissioning
400 50 3.5 1.5 0.73 84.5% 970 380 - 420 3.55-3.55 (see page 31.)
690 Y 50 2.05 1.5 0.73 84.5% 970 660 - 725 2.05-2.05
460 60 3.15 1.5 0.69 86.5% 1175 K
1 2 3 4 5

If you want to adjust any flash-

ing value digit by digit (using the
UP and DOWN button might just
take too long) press the OK but-
ton longer than two seconds.
After releasing the button, you
can change each single digit by
using the buttons OK (move to
next digit), ESC (move to previ-
ous digit), UP (increase value)
and DOWN (decrease value).

Note
32 Operator Panels BOP-2 and IOP:   Quick commissioning

I_DT_G120_Booklet_RZ.indd 32 04.04.2012 13:12:17

 Motor data identification
After entering the motor data, the wizards asks to activate the motor data identification. This is recom-
mended for a live verification and optimization of the data that you have entered. The motor data iden-
tification initiates a “measurement” of the connected motor. In the process, the data previously calcu-
lated in the converter are compared to the actual motor data and adapted to one another.

Activating motor data identification (P1900)

• Press OK to confirm MOT ID

• Change the displayed value to 1 by pressing UP

OK

Motor data identification does only start after the basic commissioning sequence has been completed
and the motor is switched on the first time!

Specifying application parameters

In the next step, pre-defined settings for the converter’s interfaces can be activated. This is stored in
parameter number 15 and indicated by MAc PAr for macro parameterization. For example, the converter
offers different pre-defined macros for setting the command and setpoint source.

Activating pre-defined settings (P15) e.g. for command and setpoint source

• Press OK to activate macro parameterization MAc PAr

• Macro 12 (Std ASP) is displayed, it determines DI 0 for the command source and the
potentiometer for the setpoint source
• Leave the value and confirm by pressing OK

OK OK

The converter can now be turned on using digital input DI 0.

The setpoint source is specified as the potentiometer.

33

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 Minimum frequency, ramp up and ramp down time (P1080)

• Set the minimum frequency under parameter MIN RPM

• Press OK (Parameter MIN RPM)
• Change the value by pressing UP or DOWN
• Press OK to confirm

OK OK

• Set the ramping-up time under parameter RAMP UP for acceleration time to maximum
frequency (P1120)
• Set the ramping-down time under parameter RAMP DWN for time until standstill (P1121)

OK OK

OK OK

The values are displayed in seconds. In both cases, the times indicated should not be too short, because
this might result in an alarm.

Completing quick commissioning

• Press OK while the BOP-2 shows FINISH

Changing the value digit by digit
• Select YES and press OK again
is possible by pressing the OK but-
ton longer than 2 seconds. After
OK OK releasing the button, each single
digit can be changed by using the
buttons OK (move to next digit),
The converter is now parameterized optimally to your application and ESC (move to previous digit), UP
(increase value) and DOWN
motor specifications. Now motor data identification should be per-
(decrease value).
formed to finalize the commissioning. This can be done by switching
on the motor. At the moment, command source is set to digital input Refer to the “Parameter Manual:
DI 0. Start the motor with turning on DI 0. Control Units – CU240E/B-2” for a
description of the control modes
and their corresponding parame-
ter settings at: http://support.
automation.siemens.com/WW/
view/en/49946755

Note
34 Operator Panels BOP-2 and IOP:   Quick commissioning

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 Motor data identification

• Start the motor manually by using digital input DI 0

• The measuring process is set in motion
• When finished, the motor switches off
• BOP-2 indicates that the measured values are now being converted into data

Saving and restoring data

Saving data in different location is important. The EXTRAS function allows loading parameter data from
the converter memory to the BOP-2 and vice versa.

Saving parameter sets from converter to BOP-2

• Navigate with the menu bar to the function EXTRAS

• Press OK
• Push the DOWN button until TO BOP appears
• Press OK

OK OK

Copying parameter sets from BOP-2 to converter

• Navigate to the menu EXTRAS

• Press OK
• Push the DOWN button until FROM BOP appears
• Press OK

OK OK

The Basic Operator Panel 2 can also be used to make a variety of other
adjustments to your application. Please note that an overview of the
parameter numbers can be found in the Operating Instructions: Con-
trol Units CU240E-2.

The BOP-2 can be mounted or

removed at any time. The device
is not necessary for ongoing
operation.

Note 35

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 2.4 Intelligent Operator Panel
With the Intelligent Operator Panel, you can set the inverter parameters, put the inverter into operation,
monitor the ongoing operation of the motor, and get valuable information about faults and alarms. All
these functions can be accessed without expert knowledge. The main advantages are as follows:

Fast commissioning without expert knowledge

• Simple commissioning of standard applications using application-specific assistants, no

knowledge of parameter structure necessary
• User customized parameter lists with reduced parameter sets
• Simple local commissioning using the handheld version
• Fast multiple commissioning with clone function
• Commissioning without documentation by using the integrated help function

Minimization of maintenance time

• Diagnosis with clear text display, without documentation usable on site

• Simple update of languages, application assistants and firmware using the
integrated USB connection
• Integrated clear text help function to read and resolve fault messages and reasons locally

High usability, intuitive handling

• Direct, manual control of the drive – simple switching from local to remote operation
• Intuitive menu navigation using wheel-click interface
• Graphical display for i.e. status values in vertical-bar charts (for example pressure or flow rate)
• Status display with freely selectable units – display of real, physical values

Flexible usage

• Available for direct control unit mounting, for door mounting or as handheld version
(depending on frequency converter type)
• Simple and fast mechanical and electrical door mounting
• Handheld usable for a large variety of frequency converters
• 5 integrated languages

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 The device
The IOP is a menu-driven device. Its functionality is structured by three options:

1 [Wizards] Assists you to set up standard

applications
2 [Control] Allows you to change setpoint
value, turning direction activates the
jog function in real-time
1 2 3
3 [Menu] Gives you access to all possible
functionalities

The display

All necessary information is user-friendly displayed in plain text or icons. The displayed icons are
shown at the top right-hand edge of the display. They indicate various states of the converter.

• Command source auto / hand

• Inverter status ready / running

• Fault

• Alarm pending

• Battery condition Fully Charged / Discharged

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 Working with IOP
The IOP is operated mainly by using the push-wheel. The five additional buttons make it possible to
display certain values or to switch between manual and auto mode. The buttons are called: ON key,
OFF key, ESC key, Info key and HAND/AUTO key.

1 Turning changes the selection

Pressing confirms the selection
2 Starts the motor in manual
mode
3 Stops the motor in manual
mode
4 Takes you back to the previous
screen
5 Displays additional
information
6 Switches the command source
between HAND and AUTO
4 5 mode
1

3 6 2

The HAND/AUTO function works

identically to the one imple-
mented in the BOP-2. After start-
ing the motor with the ON but-
ton, you can change the setpoint
speed by navigating to CON-
TROL/SETPOINT and turning the
wheel (right to increase speed,
left to decrease speed).

Note
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 The wizards
There are several wizards which allow you to set up various functions and commission the converter.
They navigate you interactively through the parameterization of standard applications. The wizards are
accessed from the wizard menu, at the bottom-left of the status screen.

Example: Basic commissioning

• Use the wheel to highlight the word WIZARDS

• Confirm by pressing OK
• Navigate to BASIC COMMISSIONING by turning the wheel
• Confirm by pressing OK

OK Wizards OK OK Basic Commissioning OK

Now the wizard will guide you step by step through the basic commissioning process by presenting a
number of screens where you can choose the necessary options and values. At the conclusion of the
basic commissioning process, the data can be saved to the converters memory, and calculation of motor
and control data is started.
• Always use the wheel to select an option and press OK to confirm
• Press ESC to move back one step
• Press INFO to read context-sensitive help information

On the top of the screen, you

can see numbers that indicate
the present step of the wizard
that you are in. 2/15 for example
means that you are in step 2 of
15.

Note 39

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 Accessing diagnostics
If you want to find out which input and output devices are connected to the converter, simply navigate
to the diagnostics menu and select the I/O STATUS. This option displays a list of the digital and analog
inputs and outputs of the converter. In addition, you can monitor their current status. This is an infor-
mation screen and cannot be changed.

Reading the I/O status

• Use the wheel to highlight the word MENU

• Confirm by pressing OK
• Select DIAGNOSTICS
• Confirm by pressing OK
• Choose I/O STATUS
• Confirm by pressing OK
• Choose STATUS DIGITAL INPUTS
• Confirm by pressing OK

OK Menu OK OK Diagnostics OK

OK I/O Status OK OK Status Digital Inputs OK

You can now see a clearly arranged overview of all connected I/O including their status.

Using the button INFO, always

gives you more in-depth infor-
mation on the presently high-
lighted parameter, step or
feature.

Note
40 Operator Panels BOP-2 and IOP:   Intelligent Operator Panel

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 Getting information on active faults

• Use the wheel to highlight the word MENU

• Confirm by pressing OK
• Choose DIAGNOSTICS
• Confirm by pressing OK
• Select ACTIVE FAULTS/ALARMS

OK Menu OK OK Diagnostics OK

OK Active Faults/Alarms OK

Now, all active fault messages that have not yet been acknowledged are displayed.
To get further information, you can highlight each one and press INFO.

You now know how to use the Operator Panels to set the parameters on your converter and start it
up. A further possibility is setting up the parameters using your PC or a SIMATIC programming device.
This method is clearer and more convenient, but requires somewhat more preparation time.

If you want to find out about

previous faults and alarms,
please navigate back one level
and select “History”. This will dis-
play a list of all previous faults
and alarms including the time
they occurred.

Note 41

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 In the next step, you will learn how to connect your PC or
PG to the converter and how to set parameters with the
STARTER software. With STARTER, you can also easily
­activate the Safety Integrated functions of the drive.

42

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3 04.04.2012 13:12:18
 STARTER software and PC

43

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 3.1 Mounting and preparation
The optional PC Connection Kit 2 is required to set up the parameters using a PC.
The kit consists of two components.

1 Connecting cable
2 STARTER software on DVD

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 Hardware preparation

• Place the STARTER DVD into your DVD drive

• Install the STARTER software by following the setup wizard
• Connect the USB cable to the Control Unit
• Connect the other end to the USB interface of your PC

You must install the USB driver if you are connecting the converter and PC together for the first time.
Windows 7 automatically installs the driver; for older Windows versions, you must confirm the auto-
matic installation.

The STARTER is also available as

a download at: http://support.
automation.siemens.com/WW/
view/en/26233208

Note 45

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 Creating a STARTER project
After installation is complete, switch on the converter’s power supply and start the program. The project
wizard opens automatically. The wizard will help you create your first project.
1 Select “Find drive units online”
2 Give the project a name and click “Continue”

1 2

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 3 Check that “DEVICE” is set as Access point. If not, choose “Access point ...” and set “DEVICE” in the dialog box “Set Access
Point for Accessible Nodes”. Check that “S7USB” is set as interface. If not, choose “PG/PC ...”.
4 Open the drop-down menu “Access Point of the Application”
5 Choose the command “DEVICE (STARTER – SCOUT) --> S7USB”
6 In “Interface Parameter Assignment Used” select “S7USB”
7 Close with OK

4
5

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 8 The identified converter is displayed
9 Add the converter to your project with “Insert drive units”
10 Close the project wizard with “Complete”

The converter is now integrated into the project tree and the parameters can be set up using the
STARTER software.

8 10

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 STARTER user interface
1 Project tree
2 Program menu
3 Toolbar with special features
4 Icon “Connect to selected target devices”
5 Connection mode
6 Work area

2 4
3

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 Loading converter data
Before you can load the current converter’s data into your project, an online connection between the
PC and the converter has to be established.
1 Click the icon “Connect to selected target devices”
2 Set the access point to “DEVICE” and place a checkmark next to converter name
3 Click “Load HW configuration to PG”

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 Now the converter data is loaded into the project and an online connection between PC and converter
is established.
4 The blue highlighted “Offline mode” changes to the yellow highlighted “Online mode”
5 The workbench area opens

Workbench area

The area provides additional information such as alarms, the target system output and the
d
­ iagnostics overview. It also stores additional operating features.

51

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 3.2 Parameterization
You can now begin to parameterize your converter.
1 Double-click on the converter icon in the project tree
2 Click on “Load CPU / drive unit to PG”

1
2

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 3 Double-click “Configuration”
4 Click “Wizard ...” in the work area and let the wizard guide you

We recommend parameterizing our

example using the online mode.

Note 53

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 Configuration wizard
The configuration wizard guides you step by step through the following parameters:
• Control structure
• Defaults of the setpoint source and the command source
• Drive setting
• Motor
• Motor data
• Drive functions
• Important parameters
• Calculation of the motor data
• Summary
By clicking “Next” you get to the next configuration step.

1 2

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 1 Start by setting the control structure
2 Define the command and setpoint source
3 Select the motor type
4 Input motor data corresponding to the rating plate

3 4

For non-Siemens motors, please

use the motor rating plate to
input the motor data.

Note 55

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 5 Select “Identify motor data at standstill” for motor data identification
6 Enter maximum current
7 Enter minimum and maximum speed
8 Enter ramp-up, ramp-down time and OFF3 ramp-down time emergency shut-off

6
7

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 After clicking “Next”, the calculating of the motor data starts. This concludes the parameterization with
the configuration wizard. You will now receive a summary of all parameter values input. The summary
can be inserted into a text file by pressing the “Copy text to clipboard” button. Finally select “Copy RAM
to ROM” to store the parameterization in the converters ROM memory and close the window by clicking
“Finish”.

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 Safety Integrated
If your converter is used in a safety related environment, we strongly recommend performing Safety
Integrated engineering using the STARTER. STARTER guides you clearly and easily through the process.
Thus, the risk of wrong parameterization is reduced to a minimum.
All control units CU240E-2 come with the Safety Integrated function STO (Safe Torque Off). STO can be
used when the motor can decelerate to a standstill within a short period of time. Activating the STO
function, immediately ensures that the motor cannot supply any further torque-generating energy.
Advantages for the user:
• No wearing parts thanks to electronic shutdown
• Converter remains connected to the supply, it always supports full diagnostics capability
• Password protected, no manipulation of the function possible

v STO

The CU240E-2_F and CU240E-2_

DP-F Control Units have several
Safety functions integrated.
In this case, no encoder is needed.
Detailed information about
­SINAMICS Safety Integrated are
available at: www.siemens.com/
safety-integrated

Note
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 Activating Safety Integrated
1 Browse to “Safety Integrated” in the project tree
2 Select “Change settings”

3 Choose ”STO via terminal” from the drop-down menu

3
2
3

Did you know that extended

­SINAMICS Safety Integrated
functions can be used without
the need of an encoder at the
motor? This worldwide unique
feature saves installation and
engineering time, reduces sys-
tem costs and saves space. For
further instructions consult the
Safety functional manual
­SINAMICS G120 and SINAMICS
G120C using the Siemens Prod-
uct Information System (Prodis)
at: http://support.automation.
siemens.com/WW/view/
en/50736819

Note 59

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 4 If your converter is connected to a controller, set the output signal to “STO active” in the corresponding drop-down menu
5 Click on “extended settings” for further adjustments
6 Follow the STARTER instructions

6
5
4

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 Now your first Safety channel is set. For the second channel just copy the parameters. Clicking “Activate
settings” concludes the safety engineering. In the workbench area click on “Alarms” and press the
“Acknowledge” button to activate the actually safety functions.

61

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 Start motor data identification
1 Open the “Commissioning” entry in the project tree

2 Double-click “Control panel” in the project tree

3 Click on “Assume control priority!” in the workbench area

4 A setup window for command transfer opens, accept the displayed values and safety instructions

1
4
2

The pending motor data identifi-

cation is indicated by the mes-
sage “A7991” in the alarm tab.
The message tells you that motor
data identification will be per-
formed after switching the
motor on.

Note
62 STARTER software and PC:   Parameterization

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 5 Place a checkmark next to “Enables” in the workbench area

Now the STARTER software has control authority for the attached motor.
6 Click the green button to start the motor

5
6

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 Motor data identification is processed. Parameter setup has been successfully completed
when Alarm 7991 has disappeared.

64 STARTER software and PC:   Parameterization

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 3.3 Application cases
Before returning control authority from the STARTER software to the terminal, you should try controlling
the motor from the PC.

Setting setpoint specifications

1 Input 1.500 rpm in the “setpoint specification” box
2 Click the green button to start the motor
3 See how the motor runs with 1.500 rpm

1 3

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 4 Adjust the speed with the slider
5 Click the red button to stop the motor
6 Conclude the process by clicking “Give up control priority!”

All functions from the displayed control area in the STARTER will be deactivated. The control authority
has been returned to the terminal.

4
6 5

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 Saving data
A power outage may cause the loss of the parameter settings. As a result, STARTER offers
various possibilities for protecting your parameter settings.
1 Double-click the “Drive navigator” in the project tree
2 Select “Commissioning” in the work area

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 3 Select “Save data in drive (RAM to ROM)” to store the parameter settings in the converter’s EEPROM memory

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 Because you have worked in online mode, no data whatsoever have been stored in your project.
4 Click “Save data to project” to save the parameter setting in your project

Now you could disconnect the online connection to the converter by clicking the
“Disconnect from target system” icon. In our example, please continue to remain online to restore the
­converter to its factory settings.

69

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 Restoring factory settings
Resetting your converter to factory settings might be helpful if you have experienced any problems
­during parameterization.
1 Double-click the “Drive navigator”
2 Select “Commissioning”

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 3 Click “Factory settings”

The security query that is now displayed lets you know that all settings you have made will be reset.
Using the checkbox query, you will have the opportunity to save your settings to the converter’s ROM
memory beforehand.

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 4 Click “OK” to reset all converter settings to the factory setting

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 5 After reset click “Disconnect from target system”

You now know how to use STARTER to quickly and clearly insert your converter into a project, set up its
parameters, and put it into operation. Please make sure that you always remember to save the parame-
ter data to the converter and in the software before exiting a project.

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 Congratulations!
You have mastered the SINAMICS G120 Training ­Booklet.
Thank you for your time and efforts. We hope that this
tutorial has addressed all the questions you had and was
useful to you. More detailed information can be found
online.

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 Download overview

Overview of the various control unit versions

http://www.siemens.com/sinamics-g120/printmaterial
SINAMICS G120 brochure

Additional information on parameters

http://support.automation.siemens.com/WW/view/en/49946755
“Parameter Manual: Control Units – CU240B/E-2”

Detailed information about SINAMICS G120

http://support.automation.siemens.com/WW/view/en/50815575
“Operating Instructions: SINAMICS G120 Inverter with CU240B-2 and CU240E-Control Units”

Safety Integrated Function Manual

http://support.automation.siemens.com/WW/view/en/50736819

STARTER software

http://support.automation.siemens.com/WW/view/en/26233208

75

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 Siemens AG
Industry Sector
Drive Technologies
Motion Control

Subject to change
Order No.: 6FC5095-0AA85-0BA0
Dispo: 21200
04/2012 HL 11076147 EN
Printed in Germany
© Siemens AG 2012

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