Siemens Certified Service Technician Level 1

(inkl. SPS-Techniker entspr. VDMA/ZVEI)

SITRAIN:
Training for Industry
Siemens AG
Industry Sector
Gleiwitzer Str. 555
90475 NÜRNBERG SINAMICS S120 - Parameterizing and Commissioning
DEUTSCHLAND Course DR-S12-PM

siemens.com/sitrain
 1 Fundamentals and overview

2 STARTER project structure

Control Units and additional system

3
components

4 STARTER connection to target device

SITRAIN
Training for Industry
5 Booksize power units

SINAMICS S120 -
6 Control word, setpoint and device trace
Parameterizing and
Commissioning 7 Topology

Course DR-S12-PM 8
Chassis power units and Cabinet
modules

Closed-loop control structure,

9
servo mode

Closed-loop control structure,

10
vector mode

11 Setpoint channel

12 Diagnostics

13 Basic positioner

Name: 14 Drive-based safety functions

Course From: To:

15 Communication
Course leader:

Course location: 16 Further drive functions

This document was created for training purposes. SIEMENS 17 Support and training
does not guarantee the content.
The reproduction, transmission, or use of this document or its
content is not permitted without express written authority.
Offenders will be liable for, inter alia, damages.
18
Copyright © Siemens AG 2016. All rights, including rights
created by patent grant or registration of a utility model or
design, are reserved.
19

SITRAIN courses on the Internet: www.siemens.com/sitrain

Course folder version: V4.7.3 (for FW 4.7 / STARTER 4.4)

20
Fundamentals .................................................................................................................................. 3
SINAMICS overview ......................................................................................................................... 9
Overview SINAMICS ........................................................................................................................ 10
The drives Family SINAMICS ........................................................................................................... 11
SINAMICS S120 overview ................................................................................................................ 12
Overview of components .................................................................................................................. 13
SINAMICS S120M ........................................................................................................................... 14
Communication among components ................................................................................................ 15
Overview of motors .......................................................................................................................... 16
STARTER engineering system ......................................................................................................... 17
Safety information for our course participants ................................................................................... 18
Exercise 1: Structure of the training equipment ................................................................................. 21

SITRAIN Page Course DR-S12-PM

Training Document 1-1 Fundamentals and overview
SITRAIN Page Course DR-S12-PM
Training Document 1-2 Fundamentals and overview
Automation The automation systems require various hardware and software components for
the machine control.

HMI The Human Machine Interface is used for the operator control and monitoring of
the machine. An HMI can consist of simple switches and lamps or a graphical
panel, part of a PC controller.

Controller The controller is the brain of the machine. Depending on the variant, it is
designated as programmable logic controller (PLC), motion controller or
industrial PC, and is responsible for open- and closed-loop control tasks in the
machine.

I/O Input and output signals (possibly distributed, this means physically separated
and connected via the bus system) and valve islands for the pneumatics.

Drives Drives are the mechanisms or processes with which an object is moved or its
movement created. This includes all types of actuators, e.g. motors and their
power units, pneumatic cylinders and their valve control, etc.

SITRAIN Page Course DR-S12-PM

Training Document 1-3 Fundamentals and overview
Controller The tasks of a programmable logic controller are the processing of I/O signals,
closed-loop control tasks and data processing.

Drive system The drive system should move a motor with a specified speed or to a defined
position. Various modules are required to do this: infeed, power units, motors,
encoders and a Control Unit.
The drive system can run independent of a higher-level controller. If a motion
control controller is deployed as higher-level controller, speed setpoints are
transferred to the various drives.
The Control Unit then uses an integrated speed and current controller to ensure
that the actual speed of the motor follows the transferred speed setpoint.

SITRAIN Page Course DR-S12-PM

Training Document 1-4 Fundamentals and overview
Converter A converter supplies a three-phase motor with a variable three-phase current.
For this purpose, the three-phase current from the supply system is rectified in
the converter and a three-phase current with variable frequency is created.

Frequencies Depending on the speed setpoint that is input, the converter outputs a frequency
of 0 to 50 Hz. Higher frequencies are also possible, depending on the motor.

Speed In some applications, a desired frequency is specified instead of the speed

setpoint. Based on the motor data, such as rated current, rated power and rated
speed, the converter knows which output frequency needs to be produced and
output to the motor.

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Training Document 1-5 Fundamentals and overview
Rectifier In a rectifier circuit, the three-phase current from the power supply is rectified.
The module for rectifying is also called the Infeed or Line Module.
Depending on the version, these modules can feed energy to the DC link or
from the DC link to the line.

DC link The DC voltage from the infeed is applied to the DC link, which is buffered using
capacitors. These capacitors are used to store the energy and are integrated
into the infeed and the inverter modules.

Inverter A power unit with transistors takes this DC voltage and generates a three-phase
current with a variable frequency and voltage from it.
The module is also referred to as a Motor Module.

Closed-loop control For open-loop and closed-loop control of these modules, a module is needed to
handle the application requirements and control and regulate the modules
accordingly.

Note The diagram above shows the principle of how a converter works. Today,
(almost) all converters for three-phase motors function according to this
principle. Additional components such as reactors, fuses, braking resistors, etc.,
are not shown.

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Training Document 1-6 Fundamentals and overview
Modular system In a modular drive system, several modules of one type can be used in the drive
system. For example, several inverters (Motor Modules) can be connected to a
DC link.

Energy exchange Energy exchange can relieve the strain on the infeed/regenerative feedback
unit; even then a diode rectifier may be sufficient.
Efficiency via the DC link connection is better than with energy exchange via the
supply system. In the latter case, the power unit of an infeed/regenerative
feedback unit would be involved in the process twice.

Retraction motion With machine tools and production machines, individual axes may need to be
retracted in order to protect tools or products in the event of a power failure.
Decelerating other drives (e.g. main spindle) means that energy is still available
for active motions.
The following must be taken into account:
• What is the most inefficient operating instance with the lowest kinetic
energy?
• The control electronics must still be supplied with power (differs according to
the converter type)

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Training Document 1-7 Fundamentals and overview
Control Unit The closed-loop and open-loop control unit is also referred to as the Control
Unit. It controls and regulates the drive modules with which it exchanges data
via a communication bus (DRIVE-CLiQ).
It is also the communication interface to the application. A speed setpoint, for
example is connected here via an analog input or a PROFIBUS network.
Line-side
components Line-side power components are fuses, contactors, reactors and filters, which
are required for switching the energy supply and meeting EMC requirements.
DC link
components DC link components are used optionally to stabilize the DC link voltage.

Motor-side
components Motor side (output side) components are motor reactors or sine filters, for
example.

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Training Document 1-8 Fundamentals and overview
Blocksize format Blocksize format units are optimized for single-axis applications and are
supplied only as Power Modules. The CU310 Control Unit can be snapped onto
them directly. The devices are cooled with an internal air cooling.
Booksize Compact
format Derived from the Booksize format, we have developed the Booksize Compact
format for machines that place particularly high requirements on the
compactness of their drives. The Booksize Compact format is thus particularly
suitable for integration into machines with high dynamic requirements and
confined installation conditions.

Booksize format Booksize format units are optimized for multi-axis applications and are mounted
adjacent to one another. The connection for the common DC link is an integral
feature.

Chassis format Higher-output units (approximately 100 kW and above) are constructed in
Chassis format. These are available as Line Modules, Power Modules and
Motor Modules. Chassis format units are cooled by an internal air cooling circuit
as standard. For special applications, e.g. for extrusion or marine applications,
liquid-cooled devices can be ordered.

Cabinet format Ready-to-use cabinet units are available for largest power ranges.

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Training Document 1-9 Fundamentals and overview
SINAMICS V These inverters focus on the essential issues, regarding both the hardware as
well as the functionality. This results in a high degree of robustness – and at the
same time low investment costs for the user.
Operation is directly at the inverter itself without having to use any additional
engineering tools. SINAMICS V are especially suitable for applications that do
not require any special drive know-how.

SINAMICS G In operation, SINAMICS G inverters fully utilize their technological strengths.

They are available from 0.37 kW up to 250 kW (0.5hp up to 400hp). Users
benefit from their standard and straightforward operating concept. This
minimizes training and service costs. And last but not least, SINAMICS G
inverters are attractive as a result of optimum price-performance ratio.

SINAMICS S SINAMICS S are predestined to address complex applications in plant and

machinery construction – as well as for the widest range of motion control tasks.
They set themselves apart as a result of an outstanding feature: the highest
degree of standard and integrated engineering.

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Training Document 1 - 10 Fundamentals and overview
SITRAIN Page Course DR-S12-PM
Training Document 1 - 11 Fundamentals and overview
SITRAIN Page Course DR-S12-PM
Training Document 1 - 12 Fundamentals and overview
AC/AC devices On AC/AC devices, the infeed and motor power supply functions are combined
in one device, the Power Module – available in Blocksize and Chassis formats.
For single-axis applications, drive control functions are performed by a special
Control Unit (CU310) mounted on the Power Module and for multi-axis
applications, by a Control Unit (e.g. CU320) connected by a DRIVE-CLiQ link. In
this case, a CU adapter is mounted on the Power Module in place of the Control
Unit.

DC/AC devices DC/AC devices (= Motor Modules) – available in Compact Booksize, Booksize
and Chassis formats – are characterized by their modular design.
SINAMICS S120 Cabinet Modules are components forming part of a modular
cabinet system for multi-motor drives with a central line infeed and a common
DC busbar of the type typically used in, for example, paper-making machines,
roller mills, test stands, or hoisting gear.
As standard, they are installed side by side in a row. Other installation types
(e.g. back-to-back) are possible on request.

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Training Document 1 - 13 Fundamentals and overview
CU320-2 For open- and closed-loop control of the drive units. A Control Unit CU320-2
can be used to couple up to several drives via Single and Double Motor
Modules. The number of drives is dependent on the mode.
CU310-2 CU310 Control Units are designed to control a single drive. They feature as
standard a PROFIBUS interface (CU310-2 DP) or a PROFINET interface
(CU310-2 PN) and a TTL/HTL or SSI encoder evaluation.
Line Module Line Modules generate a DC voltage from the line voltage and supply Motor
Modules with energy via the DC link. A distinction is made between the Basic,
Smart and Active Line Modules.
Motor Module Motor Modules are responsible for the power unit of the individual drives.
A distinction is made between
• Single Motor Modules for one drive
• Double Motor Modules for two drives
In principle, all Single and Double Motor Modules can be operated on Basic
Line Modules, Smart Line Modules or Active Line Modules for the appropriate
voltage range.
A wide range of single-axis and two-axis Motor Modules with graded current/
power ratings can be supplied.
DC link
components DC link components are available as Braking Modules, braking resistors,
Capacitor Modules and Control Supply Modules. The DC link components also
allow the implementation of multi-line constructions.
Electronic
components Further digital and analog inputs/outputs can be connected to the system using
the expansion components. Functions such as measuring probes or output
cams can be implemented.

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Training Document 1 - 14 Fundamentals and overview
S120M The S120M is a servo motor in the IP65 degree of protection with integrated
Power Module
- With/without holding brake
- Absolute encoder with 20-bit resolution per revolution or 12-bit multiturn
- The SINAMICS S120M is connected using a hybrid cable (power supply and
bus line for closed-loop control) to the Adapter Module 600 of the SINAMICS
S120 central drive system. The open- and closed-loop control of the S120M is
also made from the central drive system.

AM600 The Adapter Module 600 (AM600) is the interface between the central
SINAMICS (Booksize) components and the S120M integrated in the motor. The
AM600 is implemented in the Booksize Compact format with 75 mm module
width and opens a line of distributed S120M drives. Correspondingly, the DC-
link connections, the 24 V electronic power supply, the status LEDs, the DQ
sockets and the terminal strips are arranged and labeled similarly

Hybrid cable The pre-assembled hybrid cable already contains the signal and power cable in
a single cable. This reduces the time required for the wiring and for cutting
cables to length.
• Maximum permissible line length per Adapter Module 600: 100 m
• Segment length between an AM600 and the first node: ≥ 3 m ... ≤ 75 m
Segment length between two S120M: maximum 75 m
The complete cable length of the motor + hybrid cable depends on the central
power infeed (Line Modules)

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Training Document 1 - 15 Fundamentals and overview
Communication The communication between the Control Unit and the individual components of
the drive system is carried out via DRIVE-CLiQ, an Ethernet-based
communication protocol.

DRIVE-CLiQ The internal drive communication has the following properties and features:
• Connects all components including motors and encoders.
• Implements the connection of drive-related I/Os and encoder systems
integrated in the motor.
• Encoders in DRIVE-CLIQ motors are powered via a 24 V supply integrated
in the cable.
• Uniform design of cables and connectors reduces part diversity, storage
costs and commissioning work.

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Training Document 1 - 16 Fundamentals and overview
Motor spectrum Not only Siemens motors, but also third-party motors, can be connected to
SINAMICS.
SINAMICS S120 is optimized for the operation with Siemens motors.

Preferred motors for production machines:

• 1F synchronous servo motors
• 1PH asynchronous servo motors

Innovative machine solutions with

• 1FN linear motors
• 1FW torque motors (e.g. for extruders, rotary tables or servo presses)

Rating plate data With SINAMICS S120, it is also possible to use third-party motors. Only the
rating plate data needs to be entered for induction motors. The system can
determine the remaining data using stationary or rotating measurement.

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Training Document 1 - 17 Fundamentals and overview
SIZER This tool will support you during the technical configuration of the hardware and
software components required for automation including calculation of the load
machine.
The results can be exported in different formats for order processing or
documentation.
In a future version, the data of the STARTER service tool will also be supplied
with the information from the SIZER project.
For detailed specification of low-voltage standard motors, the SIZER can
incorporate the DT configurator.
Furthermore, the MOTOX gear designer can be used for standard gear motors.

STARTER The STARTER standalone tool is provided for easy, guided, graphics-oriented
start-up of the SINAMICS and MICROMASTER drive units; it is also integrated
in the SIMATIC Manager as part of DriveES Basic.
The tool also allows high-level expert access with comprehensive diagnostics
and trace functions.

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Training Document 1 - 18 Fundamentals and overview
SITRAIN Page Course DR-S12-PM
Training Document 1 - 19 Fundamentals and overview
SITRAIN Page Course DR-S12-PM
Training Document 1 - 20 Fundamentals and overview
Safety information Please note that:
• The course exercises have been produced for:
 A course held by the course leader
 Activities carried out on special training equipment
• The training equipment is operated under laboratory conditions.
In case of doubt, always ask your course leader – particularly when handling
components that carry electrical current or can move.
• When carrying out work on equipment, the safety information in the
associated product documentation must always be observed!
The Training Documents alone are not sufficient.

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Training Document 1 - 21 Fundamentals and overview
Task Familiarize yourself with your training equipment. Determine which components
of the SINAMICS S120 system are installed.

1. Enter the components determined for the SINAMCIS S120 converter system
above.
Order numbers are not necessary.

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Training Document 1 - 22 Fundamentals and overview
Task Determine which motors are installed.

1. Enter the data for the motors installed above.

Order numbers are not necessary.

2. Also clarify which encoder is installed.

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Training Document 1 - 23 Fundamentals and overview
Task Gain an overview of the electrical wiring.

1. Determine the most important connections:

• Where is the line infeed connected?
• Where are the motors connected?
• Where are the encoders connected?
• Where is the connection between CU 320-2 and Line Module?
• Where is the connection between CU 320-2 and Motor Module?
• Where is the switch box connected?

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Training Document 1 - 24 Fundamentals and overview
STARTER ........................................................................................................................................ 3
Drive objects .................................................................................................................................... 9
Topology .......................................................................................................................................... 14
Exercise 1: New STARTER project .................................................................................................. 18
Exercise 2: Topology and DRIVE-CLiQ connection ......................................................................... 22
Exercise 3: Project topology ............................................................................................................ 23
Exercise 4: Changing the STARTER project ..................................................................................... 24
Exercise 5: Expanding the STARTER project ................................................................................... 28

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Training Document 2-1 STARTER project structure
STARTER A user-friendly and powerful PC program is available for commissioning. With
STARTER, every inverter of the SINAMICS family can be parameterized largely
in the same way.

Wizards The drive is inserted in STARTER in the form of a project. Creation of the
project and insertion of the correct drive type is simplified by a wizard.

Offline configuration When going through the configuration, primarily the motor data, encoder data
and the interface assignment are entered.

Online commissioning Commissioning is carried out in online mode.

Control panel Using the control panel, the drive can be switched on and off for test purposes
directly from the PC. The speed setpoint is specified by the slider. Actual values
are clearly displayed.

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Training Document 2-2 STARTER project structure
Application The user-friendly STARTER drive/commissioning software can be used for:
• Commissioning
• Optimization
• Diagnostics

Integration This software can either be operated as a stand-alone PC application or it can

be integrated into the SCOUT engineering system (with SIMOTION) or STEP 7
(with Drive ES Basic). The basic functions and handling are the same in both
cases.

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Training Document 2-3 STARTER project structure
Download The current version can be downloaded directly from the Internet. Please note
the capacity of your Internet connection. The data package is approximately
2 GB.

Purchase via DVD If an Internet download is not practicable, STARTER can also be ordered on
DVD. A fee is charged for this.

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Training Document 2-4 STARTER project structure
Project navigator The project navigator displays an overview of all other elements contained in
the project. All defined elements are displayed in a tree structure.
After selection of an element, the detail view displays additional information
about the selected element.

Toolbars Frequently used menu commands are available in selectable toolbars, thus
allowing quick access to the associated functions. The toolbars can be dragged
from the header and positioned anywhere on the screen.

Work area The task-specific windows are displayed here. The actual tasks, e.g. configuring
and programming, are performed in these windows.

Detail view Further information for example about the the status of the connection to the
target device and if online about the faults and alarms of the the target device
are displayed in the detail view.

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Training Document 2-5 STARTER project structure
Graphical user
interface STARTER's graphical user interface represents signals and their characteristics
and interconnections in a way that makes them easy to understand.
Functions and input values are specified in plain text. Parameter numbers play
a subordinate role, but can be viewed if necessary using mouseover and tooltip.

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Training Document 2-6 STARTER project structure
Control panel The control panel is used for the control and monitoring of individual drives.
Drives can be operated with the control panel. This allows the commissioning
engineer:
• To test each part of the plant individually before the drives are traversed in
coordination by means of a program.
• To test, in a fault situation, whether the individual drives can be traversed by
the control panel at all, or whether these are also affected by the fault.

Selection area In the selection area of the control panel, you can select the drive you want to
monitor from the selection list in monitoring mode.
The selection list is not available in control mode.

Control area You can assume control priority of the selected drive and send motion
commands to the drive here.

Monitoring area Displays the enables, setpoints and actual values of the drive selected in the
selection area of the control panel.

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Training Document 2-7 STARTER project structure
Project structure The project navigator has a tree structure and manages hierarchically the
individual elements of a project.
The project is made up of drive units, a directory for the SINAMICS libraries and
a "Monitoring" directory. The drive units are made up of drive objects, which in
turn consist of individual components.

Drive unit The drive unit consists of a Control Unit and further drive objects.
The project tree shows the drive units (e.g. SINAMICS_S120) and drive objects
(e.g. CU_S_004, Filler_red, Transport_blue, etc.).
The drive components can be viewed under Configuration.
The project tree also shows the following in the drive units:
• Automatic configuration (only in online mode)
• Overview (of drive objects)
• Communication
• Topology
• Documentation

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Training Document 2-8 STARTER project structure
Drive unit A drive unit consists of a Control Unit and several components that are
combined to form drive objects in STARTER.

Drive object A drive object (DO) is an independent, "self-contained" software function that
has its own parameters and, in some cases, its own faults and alarms. Drive
objects can be provided as standard (e.g. evaluation of inputs/outputs), or you
can add single (e.g. Terminal Board) or multiple objects (e.g. drive control).
Overview of the drive objects:
• Drive control
The drive control handles closed-loop control of the motor. At least 1 Motor
Module and at least 1 motor and up to 3 encoders are assigned to the drive
control.
• Control Unit with inputs/outputs
• Infeed: Line Module infeed control with DRIVE-CLiQ interface
• Option Board
• Terminal Module
• External encoder
Each installed drive object is allocated a number between 0 and 62 during first
commissioning for unique identification.

Components Components are hardware modules that are assigned to drive objects in the
STARTER.

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Training Document 2-9 STARTER project structure
Drive object The drive object receives a number and a name in the configuration. These
names can be changed in the offline project.
The components that are assigned to the particular drive object are also
designated by a name and a number.
A drive object (drive control) includes:
• a power unit (Motor Module)
• a motor
• an encoder
• an encoder connection to DRIVE-CLIiQ.
The components are designated by pre-assigned names, e.g.
servo_02.motor_6.

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Training Document 2 - 10 STARTER project structure
DO configuration You must perform several steps before you can use the DO. In the first step, the
configuration creates an instance of the DO. A DO is configured with the
STARTER engineering system. You are supported by the corresponding
Wizards (parameterizing screens) to create an object and configure it.
A double-click on "Paste drive" adds a DO to the Drives directory in the project
navigator. The drive wizard then automatically starts and helps the user create
the base configuration of a drive.
Certain object-specific properties are determined in the first configuration
(e.g. Servo, Vector, Motor Module, motor, encoder).
Parameterization
screens Further settings, such as the gain factors for the speed or current control loop,
can be made from the appropriate parameterization screens. Below each DO
there is a project tree with setting screens that support configuring engineers
and commissioning engineers with their work. Each input in a parameter screen
results in the input or change of a parameter in the expert list.

Expert list In addition to access to the parameters via the wizards and parameter screens,
you can also access the data directly via an expert list.

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Training Document 2 - 11 STARTER project structure
Overview Double-click "Overview" to open the Overview window of the drive system. The
following drive objects are displayed in this window:

Closed-loop control This window displays the "Control_Unit" object and the configured option
module of the drive system.

Power units Shows the configured infeeds and drives of the drive system. For infeeds
connected in parallel, only one button is displayed.

Input/output Displays the configured input/output modules of the drive system.

Options Displays additional optional modules.

Navigation Click the corresponding module icon to open the configuration window of the
desired drive object.
The name of the drive object and the object number are displayed in this
window as well as all assigned drive components complete with the associated
component numbers.

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Training Document 2 - 12 STARTER project structure
Drive object Information about the drive object and assigned drive components is displayed
in the configuration window associated with a drive object.
The object name (e.g. "Drive_1") and the associated object number (e.g. "2")
are displayed for the drive object. The most important information about this
object is also displayed:
• Drive type (e.g. SERVO)
• Control type (e.g. speed control with encoder)
• Communication with technology via SIEMENS telegram 105
Drive
components Properties of drive components
• All drive components, such as power units, motors, encoder systems and
SMI, SMC, are identified with their associated component numbers.
• For drive components with DRIVE-CLiQ connection, the component number
is displayed in this overview. Drive components without DRIVE-CLiQ
connection are displayed without component numbers in this overview. The
numbers of these components are, however, displayed in the "Configuration
-> Version overview" window.
• For components with DRIVE-CLiQ connection, a detection for active online
connection can be performed via a flashing LED.
The most important characteristic quantities are displayed for all components.

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Training Document 2 - 13 STARTER project structure
Communication Communication between the drive units and/or components and the Control
Unit takes place via the DRIVE-CLiQ connection.

Number of ports Each component capable of communication has one or more ports for
connection of the DRIVE-CLiQ connector.
In this way, all components can be connected with the Control Unit via different
communication paths.
For example, the number of ports for
• Control Unit: 4 ports
• Active Line Module: 3 ports
• Motor Module: 3 ports
• Double Motor Module: 4 ports
• SMC: 1 port
• Terminal Module: 2 ports

Topology The component wiring is shown graphically in the topology.

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Training Document 2 - 14 STARTER project structure
Structure of topology The topology is shown as a wiring tree. The Control Unit is the first element of
the tree. All components are attached to the CU. The terminal designations
correspond to the last digit of the port designation. For example, [0] stands for
port X100. The port designations can be picked off via the tooltip.

Component number The name of the component (object name.component_name) is also indicated
in addition to the port number.
The component number is indicated in brackets.

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Training Document 2 - 15 STARTER project structure
Filter Two filters are available in the topology:
All DRIVE-CLiQ + option slot
• Display of all components with DRIVE-CLiQ connections and wiring with
DRIVE-CLiQ (status specification Activate, Deactivate and Deactivate not
present)
• Assignment of the option slot in the Control Unit (e.g. CU320)
• Display of the interface designations on the components with tooltip

<None>
• Display of the components with DRIVE-CLiQ connections and wiring with
DRIVE-CLiQ
• Assignment of the option slot in the control unit (e.g. CU320)
• Display of the encoders, motors and wiring with the drive components
• Display of all interface designations (DRIVE-CLiQ, signal cables, power
cables) using tooltip

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Training Document 2 - 16 STARTER project structure
Safety information Please note that:
• The course instructions have been produced for:
 A course held by a course leader
 Activities carried out on special training equipment
• The training equipment is operated under laboratory conditions.
In case of doubt, always ask your course leader – particularly when handling
components that carry electrical current or which can move.
• When carrying out work on equipment, the safety information in the
associated product documentation must always be observed!
The Training Documents alone are not sufficient.

SITRAIN Page Course DR-S12-PM

Training Document 2 - 17 STARTER project structure
Task Using the project wizard, create a new STARTER project with a SINAMICS
S120 drive unit
Start the project wizard
>> Project > New with Wizard > Arrange drive units offline
Project name: Porj_train_1

1. Storage location:

2. Skip the interface settings

3. As drive unit, select:

• Device: SINAMICS
• Type: S120 CU320-2 DP
• Version: 4.7
• Target device address: 1
• Name: S120_CU320_2_DP_1

4. Continue to follow the wizard

>> Paste > Next > Complete

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Training Document 2 - 18 STARTER project structure
Task Configure the drive unit
• The following specifications do not correspond to your training equipment.
• For data that is not specified, select as required.

1. Under "S120_CU320_2_DP", select

>> Configure drive unit

2. No option module: > Next

3. Infeed with DRIVE CLiQ connection: > Yes > Next

• Active Infeed, 380-480V, internal air cooling, 16 kW
• Line/DC link identification at first switch on
• Device supply voltage: 400 V
• Line filter available AIM 400 V 16 kW
• Free telegram configuration with BICO

4. Do you want to configure a drive? Yes

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Training Document 2 - 19 STARTER project structure
 5. Drive1:
• Drive pbject type:"Servo"
• Function modules: Extended setpoint channel
• Control type: Speed control (with encoder)
• Power unit: DC 510-720V, internal cooling, Single Motor Module,18A:
6SL3120-...

6. Select standard motor from list: 1PH8 induction motor

• 1PH 8103-1MG00-0BAE (2300 rpm, 7.5kW)
• Bearing version: Standard; no motor holding brake;
• Encoder 1 = Motor encoder: sine/cosine encoder incremental:; 2048 S/R;
Order number: xMxxx Code number 2001

7. Free telegram configuration with BICO

8. Configure the web server: Activate the web server

9. > Next > finish

10. Open the overview in the work area

11. Check the new tree in the project navigator. Have the 3 drive objects been
inserted: Control Unit, infeed and Drive_1?

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Training Document 2 - 20 STARTER project structure
Task In an existing project, you can check, change and expand the configuration.
Look at the configuration, and expand this by including Terminal Module TM31!

1. Check your configuration

>> S120_CU320_2_DP > Infeeds > Infeed > Configuration
>> S120_CU320_2_DP > Drives > Drive_1 > Configuration

2. In the area Input/output components insert a Terminal ModuleTM31 with

the name TM31_1:
>> Paste input/output component >name: TM31> drive object type: TM31 >
OK

3. Save your project:

>> Project > Save

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Training Document 2 - 21 STARTER project structure
Aim of the exercise The information from the topology is to be used to create the wiring of the
individual components using DRIVE-CLiQ.

Task Draw the following DRIVE-CLiQ wiring in the upper figure.

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Training Document 2 - 22 STARTER project structure
Task Analyze the topology of your project Pro_train_1

1. Open the topology:

>> S120_CU320_2_DP > Topology

2. Select the view with filter. If the filter is set to “all DRIVE-CLiQ-Objects and
option slot” you see only the components with a DRIVE-CLiQ-Interface and
the module which is inserted in the option slot e.g. TB30.

3. Select the view without filter. If the filter is set to none you see all the
components.

4. Complete the drawing above according to the DRIVE-CLiQ interconnection

shown in the topology.

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Training Document 2 - 23 STARTER project structure
Task Expand the drive unit to include an additional drive!

1. Insert a second drive:

>> Drives > Paste drive
2. Name: Drive_2, drive objects type: Servo
3. No function modules
4. Control type: Speed control (with encoder)
5. Power unit:
• 510-720 V DC
• Internal air cooling
• Type: Single Motor Modules, 6SL31.. 1.6 kW, 3A, DC/AC
• Select a standard motor from the list, motor type: 1FK7 synchronous
motor
• 1FK7022-5AK71-1SA3: 6000 rpm = 0.6 Nm, 1.4 A
• Do not use a motor holding brake
6. Encoder 1:
• Resolver, n-speed (code number: 1003)
• Details: Fine resolution G1_XIST1: Bit 11: 211 = 2048;
7. Encoder 2:
• 4096, HTL, A/B, SSI, single turn (code number: 3090)
8. Free telegram configuration with BICO > next > complete.
9. Now analyze the valid project reference topology in the views, with and
without filter:
>> S120_CU320_2_DP > Topology

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Training Document 2 - 24 STARTER project structure
Task For the purposes of the exercise, change the position of the TM31 Terminal
Module from port X103 to port X101 on the Control Unit!

1. Select the TM31, and with the left mouse key pressed, drag it to the target
(port X101 of the CU320-2DP).

2. Complete the prepared drawing for the DRIVE-CLiQ wiring.

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Training Document 2 - 25 STARTER project structure
Task In the prepared overview, list the numbers and names of the drive components
and drive objects allocated by the system.
Use the information provided by the STARTER given on the next page to do
this.

Object name Object nummer Component name Component number Type

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Training Document 2 - 26 STARTER project structure
Objects You can find the object numbers clearly arranged under the telegram
configuration:
>> S120_CU320_2_DP > Communication > Telegram configuration

Components You can find the component numbers, clearly arranged in the version overview:
>> S120_CU320_2_DP > Overview > Version overview

Note Each drive object (software unit) was also assigned a number and a name while
configuring.
You require this information for:
• configuration, communication and SW functionality
Each drive component (hardware) was assigned a number and a name while
configuring.

You require this information for:

• the topology of the DRIVE-CLiQ connections
• the assignment of the faults displayed
• a possibly necessary update of the firmware for individual components
The object and component numbers are also accessible in the configuration
screen form or via the expert list of the respective drive object.

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Training Document 2 - 27 STARTER project structure
 Drive units and objects of a project can be copied with their properties and
inserted in the same project, another project or drive unit.

Task Insert a second, identical drive unit into your project!

1. Using the right mouse key, select the S120_CU320_2_DP drive unit > Copy

2. Using the right mouse key, select your project > Paste

3. Result: a second drive unit with the name "S120_CU320_2_DP_1" is

created.

4. Select your drive unit "S120_CU320_2_DP_1", and change the name to suit
your requirements:
>> Rename

Note You can also copy individual drive objects in the same way, and re-insert them
in the appropriate subdirectory.

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Training Document 2 - 28 STARTER project structure
Task Insert an identical Drive_2 into your drive unit 1.

1. Using the right mouse key, in the project S120_CU320_2_DP_1, select

>> Drive_2 > Copy

2. Using the right mouse key, select the "Drives" directory >> Paste

3. Result: a third drive is inserted.

4. Select your drive "Drive_3", and rename it corresponding to your

requirements:
>> Rename

5. Save your project.

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Training Document 2 - 29 STARTER project structure
Overview .......................................................................................................................................... 3
Control Unit CU320-2 ....................................................................................................................... 4
CU320-2 Control Unit ....................................................................................................................... 5
Control Unit CU320-2 ....................................................................................................................... 6
Control Unit CU310-2 ....................................................................................................................... 7
CU310-2 Control Unit ....................................................................................................................... 8
Control Unit Adapters CUA31 and CUA32 ........................................................................................ 9
Option boards ................................................................................................................................... 11
Terminal Modules ............................................................................................................................. 12
Encoder connection ......................................................................................................................... 13

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Training Document 3-1 Control Units and additional system components
SITRAIN Page Course DR-S12-PM
Training Document 3-2 Control Units and additional system components
Automated system A typical automation solution often comprises a control system, drive systems
and an operator control and monitoring system. These systems communicate
via bus systems such as PROFIBUS DP or PROFINET.

Control system The control system, e.g. SIMATIC S7, handles central monitoring and
coordination of the entire automation task.

Drive system The drive system, e.g. SINAMICS, is the actuator that performs the movements
of the individual drive axes.
Operator control and
monitoring system The operator control and monitoring system, e.g. Operator Panel or Touch
Panel, represents the manufacturing process graphically depending on the
design and allows manufacturing parameters to be entered.

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Training Document 3-3 Control Units and additional system components
Connections The Control Unit CU320-2 DP / PN features the following connections and
interfaces:
• 4 x DRIVE-CLiQ sockets for communication with other DRIVE-CLiQ devices,
e.g. Motor Modules, Active Line Modules, Sensor Modules, Terminal
Modules
• 1 PROFIBUS interface with PROFIdrive V4 profile
• 2 rotary coding switches for manually setting the PROFIBUS address
or:
• 1 PROFINET interface with 2 ports (RJ45) with PROFIdrive V4 profile
• 12 parameterizable digital inputs (floating)
• 8 parameterizable bidirectional digital inputs/digital outputs (non-floating)
• 1 serial RS232 interface
• 1 interface for the BOP20 Basic Operator Panel
• 1 slot for the CompactFlash card on which firmware and parameters are
stored
• 1 slot for mounting an option module (e.g. TB30, CBE20)
• 1 Ethernet interface for commissioning and diagnostics
• 3 test sockets and one reference ground for commissioning support
• 1 connection for the electronics power supply via the 24V DC supply
connector
• 1 PE (protective earth) connection
A shield connection for the signal cable shield on the option module is located
on the CU320-2 Control Unit.
The available option slot is used to expand the connections and interfaces, for
example, to include additional terminals or for communication purposes.

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Training Document 3-4 Control Units and additional system components
CU320-2 The CU320-2 Control Units of the SINAMICS S system are designed for use
with several drives.

Number of drives The number of variable-speed drives depends on:

• the required performance
• the required special functions
• the required operating mode (servo, vector, or U/f).
The software and the parameters are stored on an insertable CompactFlash
card.

Performance license The license concept of the performance license has changed compared to
Version V4.3 of the CU320-2. Here, a performance license is required
regardless of the performance utilization beginning with the 4th axis in the
servo/vector operating mode and beginning with the 7th axis in U/f mode.

Missing license If no license is available, an alarm (A13000) is issued and the red LED SF
flashes at the CU320-2. In this case, a license must be obtained and the license
number transferred to the CompactFlash card.
Projects created for a CU320 (6SL3040-0MA00-0AAx) can be converted with
the STARTER.

Alarm A13000 The drive unit uses licensed options but the license is not sufficient. Additional
licenses are required and must be activated (p9920, p9921).

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Training Document 3-5 Control Units and additional system components
 The following information is required:
Memory card serial number (printed on the memory card)
License number, delivery note number, and the license (on the Certificate of
License)

1. Call up the "WEB License Manager".

http://www.siemens.com/automation/license

2. Choose "Direct access".

3. Enter the license number and delivery note number of the license.
--> Click "Next".

4. Enter memory card serial number.’

5. Select a product e.g. "SINAMICS S CU320-2 DP". --> Click "Next".

6. Choose "Available license numbers".--> Click "Next".

7. Check the assignment.--> Click "Assign".

8. When you are sure that the license has been correctly assigned, click "OK".

9. The license key is displayed and can be entered. Enter license key in
STARTER

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Training Document 3-6 Control Units and additional system components
Connections The CU310 DP/PN Control Unit features the following connections and
interfaces:
• 1 DRIVE-CLiQ socket for communication with other DRIVE-CLiQ devices,
e.g. Sensor Modules or Terminal Modules
• 1 PM-IF interface for communication with Power Modules in blocksize format
• 1 interface to the BOP20 Basic Operator Panel
• 1 PROFIBUS interface with PROFIdrive V4 profile
or
• 1 PROFINET interface with 2 ports (RJ45 sockets) with PROFIdrive V4
profile
• 1 encoder evaluation for the following encoder signals:
 TTL/HTL incremental encoder
 SSI encoder without incremental signals
• 4 parameterizable digital inputs (floating)
• 4 parameterizable bidirectional digital inputs/outputs (non-floating)
• 1 serial RS232 interface
• 1 slot for the CompactFlash card
• 3 test sockets and one reference ground
• 1 connection for the electronics power supply via the 24 V DC power supply
connector
• 1 PE (protective earth) connection
• 1 safe standstill input (enable pulses) for controlling the connected PM340
Power Module
• 1 temperature sensor input (KTY84-130 or PTC)

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Training Document 3-7 Control Units and additional system components
Design The CU310-2 Control Unit uses the PM-IF interface to control the Power
Modules in blocksize format. In this case, other DRIVE-CLiQ components such
as Sensor Modules or Terminal Modules can be connected to the DRIVE-CLiQ
socket on the CU310-2 Control Unit.
Power Modules in chassis format are controlled from the CU310-2 Control Unit
via the DRIVE-CLiQ interface. Here, the Sensor Modules and Terminal Modules
must be connected to the free DRIVE-CLiQ sockets on the Power Module.
Parameter settings can be changed with the BOP20 Basic Operator Panel. The
BOP20 Basic Operator Panel can also be snapped onto the CU310-2 Control
Unit during operation to perform troubleshooting procedures.

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Training Document 3-8 Control Units and additional system components
CUA31 / CUA32 The CUA 31 / CUA32 Control Unit Adapter converts the Power Module interface
to the DRIVE-CLiQ interface.

CUA32 The CUA32 Control Unit Adapter is also equipped with an integral encoder
evaluation device which can be configured for an HTL/TTL or SSI encoder.

The CUA31 / CUA32 Control Unit Adapter allows Power Modules in blocksize
format to operate on a CU320-2 or SIMOTION D Control Unit, e.g. as a single
axis in addition to a multi-axis drive.

Interfaces The CUA31 Control Unit Adapter features the following connections and
interfaces:
• 1 temperature sensor input (KTY84-130 or PTC)
• 3 DRIVE-CLiQ sockets
• 1 connection for the electronics power supply via the 24 V DC power supply
connector
• 1 safe standstill input (enable pulses)
The status of the CUA31 Control Unit Adapter is indicated via a multi-color LED.
The CUA32 Control Unit Adapter also features the following connection:
• 1 encoder evaluation
The following encoder signals can be evaluated:
• TTL/HTL incremental encoder
• SSI encoder without incremental signals

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Training Document 3-9 Control Units and additional system components
Layout with PM340 The CUA31 / CUA32 Control Unit Adapter is snapped onto the Power Module in
blocksize format and communicates with a CU320-2 or a SIMOTION D Control
Unit by means of a DRIVE-CLiQ link.

The CUA31 / CUA32 Control Unit Adapter's power is supplied by the Power
Module via the Power Module interface. If the CUA31 / CUA32 Control Unit
Adapter needs to communicate when the Power Module is switched off, it must
be supplied with 24 V DC from an external source.
Other DRIVE-CLiQ devices such as Sensor Modules or Terminal Modules can
be connected to the CUA31/CUA32 Control Unit Adapter.

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Training Document 3 - 10 Control Units and additional system components
TB30 The following are located on the TB30:
• Power supply for digital inputs/outputs
• 4 digital inputs / 4 digital outputs
• 2 analog inputs / 2 analog outputs

CBC10 The CBC10 is used to interface to the CAN (Controller Area Network) protocol.
The associated driver software fulfills the standards of the following CANopen
specifications of the CiA organization (CAN in Automation):
• Communication profiles in accordance with DS 301
• Drive profile in accordance with DSP 402 (in this case Profile Velocity Mode)
• EDS (Electronic Data Sheet) in accordance with DSP 306
• Operational status signaling in accordance with DSP 305

CBE20 The CBE20 connects to a PROFINET IO network. This makes the

SINAMICS S120 a PROFINET IO-Device as defined by PROFINET and
provides the following functions:
• PROFINET IO-Device
• 100 Mbit/s full duplex
• Supports real-time classes of PROFINET IO:
• RT (Real-Time)
• IRT (Isochronous Real-Time), minimum send cycle 500 μs
• Connection to controllers as PROFINET IO-Devices using PROFIdrive
compliant with Specification V4
• Standard TCP/IP communication to STARTER
• Integrated 4-port switch based on the PROFINET ASIC ERTEC400.
• Supports the media redundancy procedure and shared device functions.

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Training Document 3 - 11 Control Units and additional system components
TM15 The TM15 expands the CU320-2 to include additional DI/DO.

TM31 The TM31 provides a large number of additional I/Os and a PTC/KTY interface.
It constitutes the central customer interface for digital and analog inputs and
outputs in the SINAMICS cabinet units.

TM41 The TM41 supplies TTL signals which emulate an incremental encoder, e.g. to
a higher-level controller. The encoder interface (incremental encoder emulation)
can be linked to an encoder signal from the Control Unit, e.g. incremental
encoder sin/cos, by parameter assignment.

TM54F The TM54F is a dual-processor I/O interface with 4 fail-safe digital outputs and
10 fail-safe digital inputs for utilization of the Safety Integrated functions of the
SINAMICS S120 drive system over external actuators and sensors. (Safety
topic)

TM120 The TM120 is capable of evaluating up to 4 temperature sensors (KTY84-130 or

PTC). The temperature sensor inputs are safely electrically isolated from the
evaluation electronics in the TM120 Terminal Module and are suitable for
evaluating the temperature of special motors, e.g. 1FN linear motors and 1FW6
built-in torque motors.

TM150 The TM150 is a DRIVE-CLiQ component for temperature evaluation. The

temperature is measured in a temperature range from -99 °C to +250 °C for the
following temperature sensors:
• Pt100 (with monitoring for open-circuit and short-circuit)
• Pt1000 (with monitoring for open-circuit and short-circuit)
• KTY84 (with monitoring for open-circuit and short-circuit)
• PTC (with monitoring for short-circuit)

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Training Document 3 - 12 Control Units and additional system components
 • Bimetallic NC contact (without monitoring)

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Training Document 3 - ‹Nr.› Control Units and additional system components
With DRIVE-CLiQ The encoder system should be connected to SINAMICS S120 preferably via
DRIVE-CLiQ.
Motors with DRIVE-CLiQ interfaces (e.g. synchronous motors 1FK7 and 1FT6,
and induction motors 1PH7) are designed for this purpose.
These motors simplify commissioning and diagnostics because the motor and
encoder type are identified automatically.

Without DRIVE-CLiQ Motors without DRIVE-CLiQ interfaces, as well as external encoders, must be
connected via Sensor Modules to enable the encoder and temperature signals
to be evaluated.
Sensor Modules Cabinet-Mounted (SMC) are available for installation in control
cabinets and Sensor Modules External (SME) for installation outside control
cabinets.

With DRIVE-CLiQ Motors with DRIVE-CLiQ interfaces can be connected to the associated Motor
Module directly via the MOTION-CONNECT DRIVE-CLiQ cables available.
The connection of the MOTION-CONNECT DRIVE-CLiQ cable at the motor has
degree of protection IP67.
The DRIVE-CLiQ interface supplies the motor encoder via the integrated
24 V DC supply and transfers the motor encoder and temperature signals and
the electronic rating plate data, e.g. a unique identification number, rated data
(voltage, current, torque, etc.) directly to the Control Unit.
Different encoder cables are therefore no longer required for the various
encoder types, e.g. resolvers or absolute encoders. Wiring can be effected
throughout with a MOTION-CONNECT DRIVE-CLiQ cable.

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Training Document 3 - 13 Control Units and additional system components
SME20/25 SME20/SME25 Sensor Modules External are encoder evaluation units for
machine encoders (direct measuring systems). The housings are designed with
IP67 degree of protection.
The following encoder signals can be evaluated:
• Incremental encoder sin/cos 1 Vpp without rotor position track (C/D track)
• Absolute encoder EnDat
• SSI absolute encoder with incremental signals sin/cos 1 Vpp
• Neither motor nor encoder data are saved in the SME20/SME25.

SMC40 The Sensor Module Cabinet-Mounted SMC40 is used to convert encoder

signals from absolute encoders with EnDat 2.2 to DRIVE-CLiQ and send these
to the Control Unit. Two encoder systems with EnDat 2.2 can be connected to
the SMC40. Their signals are converted independent of each other to two
DRIVE-CLiQ encoder signals.

SME120/125 The SME120/SME125 Sensor Modules External are encoder evaluation units
with degree of protection IP67, especially suitable for use in linear and torque
motor applications.
• The motor temperature signals are safely electrically isolated. A Hall-effect
sensor box can be connected for the SME120 to determine the commutation
position of a linear motor.
• Neither motor nor encoder data are saved in the SME120/SME125.

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Training Document 3 - 14 Control Units and additional system components
Learning Targets .............................................................................................................................. 2
Steps in commissioning sequence .................................................................................................... 3
Connection to target device .............................................................................................................. 4
LAN interface ................................................................................................................................... 5
Access point ..................................................................................................................................... 6
Target device selection ..................................................................................................................... 7
Access point DEVICE ....................................................................................................................... 8
IP addresses .................................................................................................................................... 9
Accessible nodes ............................................................................................................................. 11
Automatic configuration .................................................................................................................... 12
Storage locations for data backups ................................................................................................... 13
Project or drive unit .......................................................................................................................... 14
Exercise 1: Structure of the training case .......................................................................................... 16
Exercise 2: Online access via LAN interface ..................................................................................... 20
Exercise 3: Configuring the drives .................................................................................................... 25
Exercise 4: Testing with control panel .............................................................................................. 35
Exercise 5: Data backup .................................................................................................................. 36
Exercise 6: Changing the IP addresses ............................................................................................ 37

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Training Document 4-1 STARTER connection to target device
STARTER A user-friendly and powerful PC program is available for commissioning. With
STARTER, every converter of the SINAMICS family can be parameterized
largely in the same way.

Wizards The drive is inserted in STARTER in the form of a project. Creation of the
project and insertion of the correct drive type is simplified by a wizard.

Offline configuration When going through the configuration, primarily the motor data, the encoder
data and the interface assignment are entered.

Online commissioning Commissioning is carried out in online mode.

Control panel Using the control panel, the drive can be switched on and off for test purposes
directly from the PC. The speed setpoint is specified by the slider. Actual values
are clearly displayed.

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Training Document 4-2 STARTER connection to target device
Online / Offline There are two options for pasting a new drive unit:
• If you can establish an online link to the drive, then this is generally the
easier option since the device variant and firmware versions are identified
automatically.
• If you cannot access the drive, then carefully input the planned devices. The
firmware versions are identified when you connect online for the first time.

Remaining steps You will be guided step by step by the prompts. You cannot terminate the
process prematurely. If you work consistently with the <Next> key, any data
already stored or determined beforehand will be displayed as default and, at the
end of the process, you will find that you have not overwritten any values by
mistake

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Training Document 4-3 STARTER connection to target device
PROFIBUS DP The PROFIBUS DP fieldbus is widely used in the automation world. As well as
controllers, input/output modules, operator panels and drives, commissioning
PCs can also communicate via this bus.
A point-to-point connection between a PC and a drive is also possible.
The PC must be equipped with a PROFIBUS DP interface.

PROFINET This fieldbus represents the further development of PROFIBUS based on

Ethernet.

LAN Ethernet interface that enables a further online access in addition to the network
interfaces.

RS232 Connection for AOP 30 (Advanced Operator Panel).

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Training Document 4-4 STARTER connection to target device
LAN interface The LAN interface (X127) of the CU320-2 enables a direct connection to be set
up between the Control Unit and the PG/PC. The LAN interface is an Ethernet
interface for communication via TCP/IP.
Network
communication The network connection (PROFIBUS-DP or PROFINET) can be used to
integrate the Control Unit in a communication network where one CPU provides
the master and/or the controller. A PG may also be integrated into this network
which can communicate with all network stations via the network.

Access point STARTER offers two access points for these two options for communication to
a Control Unit:
• DEVICE (STARTER, SCOUT)
• S7ONLINE (STEP7)
The "DEVICE“ access point is preferred for direct communication, while the
access point "S7ONLINE“ is used for communication within a network.

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Training Document 4-5 STARTER connection to target device
Access point STARTER offers the user two methods of setting up a communication
connection:
• DEVICE (STARTER, SCOUT)
• S7ONLINE (STEP7)

Parameter assignment The interface to be used for communication must be defined for both access
points.
The following sequence can be used to assign parameters:
>> Tools > Set PG/PC interface
A pulldown menu is used to select the access point to be configured.
The "Interface Parameter Assignment Used" table is used to select which
interface this access point utilizes for communication.

Example Communication between the PG and the Control Unit is carried out via the LAN
interface.
The PG has 2 LAN interfaces with names:
• LAN connection: Intel 82574L Gigabit network …. (left interface)
• LAN connection 2: Intel 82574LM Gigabit network …. (right interface)
Communication to the CU should take place via the left interface.
To do this, use an Ethernet cable to connect the LAN interface on the PG to the
LAN interface on the CU. Select the "DEVICE" access point for this direct
connection.
The "DEVICE" access point is assigned the following interface parameters:
TCP/IP- Intel 82574L Gigabit network ….

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Training Document 4-6 STARTER connection to target device
Select target devices If a project contains several drive units, you can select the devices to which a
connection is to be set up when the "Online connection" button is pressed.
In this way, it is possible to connect selectively to specific target devices.

Connect online If a drive unit is to be connected to a target device (go online), it is possible to
specify the access point (and thereby the interface) to be used to set up the
connection.

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Training Document 4-7 STARTER connection to target device
SITRAIN Page Course DR-S12-PM
Training Document 4-8 STARTER connection to target device
IP addresses Each access point for a device on a network is identified by its address. The IP
address is used in TCP/IP networks. It comprises 4 bytes and is structured
according to rules, e.g.:
192.168.0.1 (dot notation)
With the dot notation, each IP address is expressed by four decimal numbers
between 0 and 255, separated by dots.
IP addresses have two parts: the network ID and the host ID. The network ID
specifies the subnet to which the host is connected. The host ID specifies the
address of the access point for the host.

IP Classes The subdivision of an IP address into a subnet and host breaks the IP network
down into a large collection of interconnected subnets with the different sizes.
5 classes were originally defined, however only the classes A, B and C are
used.

Subnet mask A subnet mask is a filter used to identify all systems connected to the same
physical network section.
The rules for the subnet mask are very simple:
• Ones in the subnet mask identify the number part of the subnet.
• Zeros identify the part of the address that is available for the host ID.
Even if the subnet masks are not used, the hardware automatically defines the
default subnet mask for class A, B or C.

Note If send and receive stations are connected to the same network, or connected
directly by a crossed Ethernet cable, the network ID of both IP addresses must
match.

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Training Document 4-9 STARTER connection to target device
Changing IP address For communication between the PG and the Control Unit via the LAN interface,
the network ID of both IP addresses must match and the host addresses must
be different.

Control Unit The LAN address can be edited using the "Edit Ethernet node" tool.

PG The IP addresses of the PG are set via the network configuration. This network
configuration can also be used to assign a further IP address to the LAN
interface of the PG.
In addition, STARTER can also set up a temporary IP address. This address
remains active until STARTER is terminated.

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Training Document 4 - 10 STARTER connection to target device
 A drive can be inserted extremely conveniently into a project using this function.
This is especially useful on a network with a large number of drives, but it can
also be used for a simple point-to-point connection.

Access point The selected access point S7ONLINE or DEVICE is used to search for
accessible nodes. The access point can be selected using the "Access point"
button. The "PG/PC…" button can be used to change the interface configuration
for the access point.

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Training Document 4 - 11 STARTER connection to target device
 The topology is determined and transferred automatically to the PG using
"Automatic Configuration" (quick commissioning).

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Training Document 4 - 12 STARTER connection to target device
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Training Document 4 - 13 STARTER connection to target device
SITRAIN Page Course DR-S12-PM
Training Document 4 - 14 STARTER connection to target device
Safety information Please note that:
• The course instructions have been produced for:
 A course held by a course leader
 Activities carried out on special training equipment
• The training equipment is operated under laboratory conditions.
In case of doubt, always ask your course leader – particularly when handling
components that carry electrical current or which can move.
• When carrying out work on equipment, the safety information in the
associated product documentation must always be observed!
The Training Documents alone are not sufficient.

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Training Document 4 - 15 STARTER connection to target device
Task Compare your training equipment with this diagram and become familiar with
the installed components.

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Training Document 4 - 16 STARTER connection to target device
Task Compare your training equipment with this diagram and become familiar with
the installed components.

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Training Document 4 - 17 STARTER connection to target device
Task Understand the function of the switches (= inputs for the drive) and the LEDs
(= outputs for the drive).
Abbreviations:
• CU = Control Unit
• TB = Terminal Board
• DI = Digital Input
• DO = Digital Output
• AI = Analog Input
• AO = Analog Output

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Training Document 4 - 18 STARTER connection to target device
Task Check whether your training equipment corresponds to the standard structure.

1. Are all of the modules available and connected?

• In the CU320-2 module, check whether a CompactFlash card has been
inserted with a "structure" that matches the SINAMICS S120 device
currently being used.
• Check that the modules are reliably supplied with 24V DC.
• Check whether the drive components are wired according to the
DRIVE-CLiQ topology above.

2. Establish the DRIVE-CLiQ topology shown above at the training case

(if this is required).

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Training Document 4 - 19 STARTER connection to target device
Task An online connection is to be set up between the PG and the CU320-2 to initiate
automatic configuration of the training equipment and commission the drives.
Then, the parameters should be saved in ROM and in the PG.

Procedure Connect the LAN interface (left Ethernet interface viewed from the front) to the
LAN interface of the CU320-2 using an Ethernet cable.

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Training Document 4 - 20 STARTER connection to target device
 1. Create a new project with the name "S120_Servo_1“ using:
>> Project > New

2. To set up a connection to the CU320-2, the access point and the interface
configuration must be defined.
Then open the parameter screen via:
>> Tools > Set PG/PC interface…

3. At access point, select: DEVICE (STARTER, SCOUT), and for the interface
parameter assignment used:
• Windows XP: TCP/IP -> Intel® 82574L Gigabit…
• Windows 7: Intel ® 82574L Gigabit Network Connection TCPIP.1

4. Accept the parameterization with "OK".

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Training Document 4 - 21 STARTER connection to target device
Procedure The "accessible nodes" function should be used to search for nodes in the
network.

1. Click on the
>> Accessible nodes
button to start the function.
Depending on configuration of the PG interface and settings, either the
message:
• No further node found
or
• Information on accessible nodes cannot be fully displayed“ appears.

2. Acknowledge the first message with "OK" and the second message with
"No". Then, the "Accessible nodes" screen is visible.

3. Select the "Access point" button.

In this screen, you can now choose the access point (S7ONLINE or
DEVICE) to which a connection is to be established.
Click on the "DEVICE" access point.
The "Update" button initiates a search for accessible nodes via the DEVICE
access point again.

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Training Document 4 - 22 STARTER connection to target device
 4. The message "Information on accessible nodes cannot be fully displayed“
appears.

5. Since the CU320-2 CU has the IP address 169.254.11.22 and the PG has
the IP address 192.168.0.10, it is suggested that you set up a temporary
IP address to communicate with the CU.
Acknowledge this message with "Yes".

6. The node with the IP address 169.254.11.22 appears in the screen of

accessible nodes. The node is detected as a CU320-2 with firmware
version 4.6.

7. Select the drive unit and with the button “accept” you can incorporate it into
the still empty project.
This creates a project tree.

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Training Document 4 - 23 STARTER connection to target device
Task The next step is to go online (connect to tarrget system) with the project
The drive unit in the project is to be connected to CU via the "DEVICE" access
point:

1. Open the "Target Device Selection" screen via:

>> Target system -> Select target devices.

2. In this screen, you can select which drive units are to establish a connection
and define which access point is to be used to connect each drive unit in the
project to the target device.

3. Select the drive unit and the "DEVICE" access point.

4. The "Connect to selected target devices" button establishes the connection

to the CU320-2 via TCP/IP.

5. The "Target system output" diagnostics information provides information

about the access point and the IP address of the target system.

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Training Document 4 - 24 STARTER connection to target device
Task By restoring the factory settings, establish a neutral starting state, and then start
with the automatic configuration:
Procedure
1. Restore the factory settings for the drive:
Select the drive unit using the right mouse key:
>> Target device > Restore factory settings

2. Set the check mark at the "Save device parameterization to ROM after
completion" checkbox

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Training Document 4 - 25 STARTER connection to target device
 1. Carry out an "Automatic configuration":
>> Automatic configuration
[Message "Status of the drive unit: First commissioning“]

2. Start the automatic configuration:

>> Configure

3. Pre-assignment for all components:

>> SERVO > Create

4. Exit the automatic configuration using the following function:

>> Go OFFLINE

5. Select "Drive_unit_1" using the right mouse key:

>> Rename > SINAMICS_S120
 the name has been changed to "SINAMICS_S120".

Note If the CU 320-2 detects a DRIVE-CLiQ component with a different firmware

release (possibly also with hotfix), a FW upgrade/downgrade is started
automatically as of FW version 2.5.1. The message "Update in progress" is
displayed. A POWER ON must then be executed to activate the new FW
version.

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Training Document 4 - 26 STARTER connection to target device
Task In the project navigator, compare the results of the automatic configuration for
your training equipment with the above diagram:

1. SINAMICS_S120 > Communication > Telegram configuration > IF1

Drive object no. 1 = CU_S_004

Drive object no. 2 = ……………………………………..

Drive object no. 3 = ……………………………………..

Drive object no. 4 = ……………………………………..

2. Drives > Drive_02 > Configuration

Power unit order no.: ……………………………………..

Motor order no.: ……………………………………..

Encoder type: ……………………………………..

3. Drives > Drive_03 > Configuration

Power unit order no.: ……………………………………..

Motor order no.: ……………………………………..

Encoder type: ……………………………………..

4. Conclusion:

………………………………………………………………………………

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Training Document 4 - 27 STARTER connection to target device
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Training Document 4 - ‹Nr.› STARTER connection to target device
Task As only the power unit (Motor Module) and the encoder interface (SMC20) have
been identified for drive object "Servo_03", the motor and encoder data must
now be configured:

1. Configure the drive object "Servo_03":

>> Drives > Servo_03 > Configuration > Configure DDS…

2. Run through the configuration routine with the following settings for the
control structure:
• NO function modules
• Control type: Speed control (with encoder)

3. Power unit: keep the preassigned settings!

4. Power unit BICO: Here, to evaluate the feedback signal from the infeed unit,
select the following BICO interconnection:
Infeed in operation (p864): >> CU_S_004, r722: Bit 16

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Training Document 4 - 28 STARTER connection to target device
 5. Motor: Enter the motor data based on the motor order number:
>> Select a standard motor from the list
>> Motor type: 1FK7 synchronous motor …

6. Motor holding brake: >> Do not use a motor holding brake.

7. Encoder: >> Sin/cos incremental C/D (Code number: 2001) > OK

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Training Document 4 - 29 STARTER connection to target device
 8. Process data exchange (drive): Keep the default
"Free telegram configuration with BICO" and exit the drive configuration for
"SERVO_03".

9. Save the data.

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Training Document 4 - 30 STARTER connection to target device
Task The data saved in the project should now be transferred to the CU320-2.

1. Go online using the yellow button.

2. Download the data to the target device.

3. The data should then also be saved in the ROM of the target device.

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Training Document 4 - 31 STARTER connection to target device
Task As the training cases are operated with a 1-phase 230 V AC supply voltage
instead of 3-phase supply voltage, and have therefore also been adapted from
the hardware perspective, the voltage of the DC link monitoring must now also
be appropriately adapted:
The drive unit line supply voltage for the Motor Module (drive: p210) is obtained
from the line voltage and the infeed type:
U_line: 400V, controlled  U_DC_link = U_line * 1.5
(e.g.: 400V AC * 1.5 = 600V DC)
U_line: 230V, unregulated  U_DC_link = U_line * 1.43
(e.g.: 230V AC * 1.43 = 329 V DC)

Procedure On the 230 V training case, p210 must be set to 329.

In order to ensure a higher margin to the internal fault threshold
"U_DC_link_max“ in generator mode, the following setting is recommended:
>> SERVO_03, p210 = 380
To ensure that the fault threshold "U_DC_link_min" is not undershot in motor
mode:
>> SERVO_03, p278 = - 80
The upper and lower limits for DC link monitoring (p1244 = 710, p1248 = 205)
are recalculated using:
>> SERVO_03, p340 = 1
Also use these settings for SERVO_02.

Note for SINUMERIK At the 400V rack with SINUMERIK 840D solution line, the setting remains:
p210 = 600.

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Training Document 4 - 32 STARTER connection to target device
Task The training case has an infeed (Smart Line Module) without DRIVE-CLiQ
connection to the CU320. The infeed provides a ready signal via terminal X21.
On the training equipment, this signal is routed to the digital input DI16 of the
CU.
In addition to the control signals, each drive also requires the signal "Infeed
ready" for the enable.
This signal must be applied to parameter p864.

1. Open the expert list of the drive.

2. At parameter "p864: Infeed operation", the digital input of the CU to which

the infeed signal is connected must be specified.

3. Go to the line of p864. Click on the value of the parameter to open the value
screen.

4. Select "CU_S_004" as signal source and the parameter value p722: bit16.
The result is then:
p864: CU_S_004: r722.16

5. Check this parameter assignment also for the "SERVO_02" drive.

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Training Document 4 - 33 STARTER connection to target device
 8. The drives in the trainingsrack may turn only with a maximum speed of 6000
rpm. Using the automatic setting the rated motor speed is set to 6000 rpm
and the maximum speed is set to 10000 rpm. Change the maximum speed
to 6000 rpm in the menue: drive >> open loop/closed loop control >>
speed controller >> speed setpoint limit: n_max: 6000 rpm.

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Training Document 4 - 34 STARTER connection to target device
Task Test the drive function using the control panel:

1. Activate the control panel for SERVO_02:

>> Drives > SERVO_02 > Commissioning > Control panel
2. If required, shift the screen split somewhat towards the top
3. Using the appropriate button, select:
• “Show control area“
• "Show diagnostics area"
4. Assume control priority – and observe the safety notes under all
circumstances
5. Press the "Diagnostics" button and select the "Missing enables“ tab:
Observe the missing enables!
6. Set the required enables
7. Now observe the feedback messages:
• OFF1 enable missing
• Speed controller inhibited
8. Set the scaling slider to 0%
8. For the 100% setpoint, for example, specify 1000 rpm
9. Now issue the ON command using the green button and monitor the drive.
10. Change the scaling:
The drive can be operated between 0 and 2000 rpm.
Monitor the setpoint and actual value display
11. After the test has been successfully completed, give up the control priority.
12. Test SERVO_03 in the same way.

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Training Document 4 - 35 STARTER connection to target device
Task After the drives have been tested using the control panel, the data can be
saved. The data should be saved both to ROM (and therefore on the CF card)
and to the hard disk of the PG:

1. To save the data to ROM, press the "Copy RAM to ROM" icon.

2. To save the data in the PG, press the "Load drive unit to PG" icon and then
save the data to the hard disk using the "Save project" icon.

This ensures that the same parameter values are present both in the PG and in
the control after restart.

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Training Document 4 - 36 STARTER connection to target device
Task The "Accessible nodes" function has added a further temporary IP address in
the PG, which can set up communication to the CU320-2.
This IP address is deleted again when STARTER is exited.
If STARTER is restarted, no online connection would be set up, since the
temporary IP address is no longer available.
In this case, it is necessary either to assign a non-temporary IP address to the
PG or to change the IP address of the CU 320-2.
In this exercise, a further non-temporary IP address is assigned to the PG
initially.
The last step shows how to change the IP address of the CU320-2 if it is not
possible to adapt the IP address of the PG.

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Training Document 4 - 37 STARTER connection to target device
Task The IP addresses of both Ethernet interfaces of the PGs are configured via the
network connections. In this task, a further IP address is to be added to an
existing one.

Procedure The IP addresses of the LAN interfaces of the PG can be read and changed via
the network connections.
Another method is via the PG/PC interface:

1. Open the "Set PG/PC Interface" screen. If "DEVICE" is selected as the

access point, TCP/IP… is shown as interface configuration.’

2. "Properties" and "Network properties" enable you to access the network

connections.

If you select the LAN interface, you can use the context menu to read out and
modify the properties.

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Training Document 4 - 38 STARTER connection to target device
Procedure If a fixed IP address is assigned to the PG, the "Add" button can be used to add
new IP address:

Procedure Add the new IP address 169.254.11.10 with subnet mask 255.255.0.0. If "Obtain
an IP address automatically" is set in the properties, the "Alternate
configuration" tab can be used to enter a further IP address. This is not the case
for our training PG but could be for PCs that are integrated into the network.

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Training Document 4 - 39 STARTER connection to target device
Procedure The IP address of the LAN interface of the CU320 can also be changed and
thereby matched to the IP addresses of the communications partners:

1. The "Accessible nodes" button shows the nodes in the network and is used
to create a temporary IP address in the PG, if this is required.

2. The context menu of the mode enables you to access the "Edit Ethernet
node …“ function.

3. The screen that follows can be used to output the IP and MAC addresses of
the nodes.

4. The IP address of an individually selected node can also be changed in this

screen.

5. Nodes that are integrated in a PROFINET network can also be assigned a

device name.

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Training Document 4 - 40 STARTER connection to target device
Component overview ....................................................................................................................... 3
Line-side Power Modules ................................................................................................................. 4
Line-side Power Modules ................................................................................................................ 5
Line-side Power Modules ................................................................................................................. 9
Drive unit line supply voltage ............................................................................................................ 11
DC link components ......................................................................................................................... 13
Motor-side Power Modules ............................................................................................................... 19

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Training Document 5-1 Line and motor modules booksize
SITRAIN Page Course DR-S12-PM
Training Document 5-2 Line and motor modules booksize
Line Modules For supplying the motor power. A distinction is made between the Basic Line
Module, Smart Line Module and Active Line Module.

Motor Modules The Motor Module is responsible for the power unit of a drive. A differentiation is
made between Single Motor Modules for one drive and Double Motor Modules
for two drives.
DC-link
components Braking Modules, braking resistors, Capacitor Modules and Control Supply
Modules are available as DC link components.
DC link components allow the modules to be implemented in multi-tier
arrangements.
Line-side
components Line-side power components are fuses, contactors, reactors and filters, which
are required for switching the energy supply and meeting EMC requirements.
Motor-side / load-side
components Motor side components are motor reactors or sine filters, for example.
Additional system
components Further digital and analog inputs/outputs can be connected to the system using
the expansion components. Functions such as measuring probes or output
cams can be implemented.

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Training Document 5-3 Line and motor modules booksize
SITRAIN Page Course DR-S12-PM
Training Document 5-4 Line and motor modules booksize
Properties Properties of the Basic Line Module "booksize" format:
• Unregulated infeed unit with diode bridge (B6 circuit)
• Pre-charging via the pre-charging resistors with time monitoring
• Not capable of energy recovery
• Integrated protective functions (overtemperature, DC link undervoltage/
overvoltage, phase failure)
• Dimensioned for continuous rated current (power overload possible at
reduced rated current)

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Training Document 5-5 Line and motor modules booksize
Properties Properties of the Basic Line Module in "chassis" format:
• Unregulated infeed unit with thyristor technology (B6 circuit)
• Integrated time-controlled pre-charging via firing angle (no pre-charging
resistors)
• Not capable of energy recovery
• Integrated protective functions (overtemperature, DC link undervoltage/
overvoltage, phase failure)
• Dimensioned for continuous rated current (power overload possible at
reduced rated current)
• Line-side reactor with 2% uk normally required
• Infeed of an external 24 V supply necessary

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Training Document 5-6 Line and motor modules booksize
Properties Properties of the Smart Line Module:
• Unregulated infeed/regenerative feedback unit in IGBT technology
• External pre-charging through line-side contactors and resistors
• Stable regenerative feedback by using IGBT modules. Prevention of
switching losses results in better utilization of the IGBT modules
• Integrated protective functions (overtemperature, DC link undervoltage/
overvoltage, phase failure)
• Dimensioned for continuous rated current (power overload possible at
reduced rated current)
• Line-side reactor with 4% uk normally required

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Training Document 5-7 Line and motor modules booksize
Properties Properties of the Active Line Module:
• Regulated infeed/regenerative feedback unit in IGBT technology
• Pre-charging in the Active Interface Module through contactors and resistors
• Unrestricted line feedback
• Step-up converter (boost) operation enables regulated DC link voltage and
sinusoidal line currents
• Innovative Clean Power Filter for minimum line harmonic distortion
• Reactive power compensation possible
• Integrated protective functions (overtemperature, DC link undervoltage/
overvoltage, phase failure)
• Dimensioned for continuous rated current (power overload possible at
reduced rated current)
• Line-side reactor required for step-up converter operation

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Training Document 5-8 Line and motor modules booksize
Notes

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Training Document 5-9 Line and motor modules booksize
Infeed operation With a Basic Line Module or Smart Line Module that does not have a DRIVE-
CLiQ connection, the "Infeed Ready" signal is sent to the outside via connector
X21.1 (DO: Ready).
The signal is set by the module to "1" ("High level") if the following conditions
are fulfilled:
• Electronic power supply (X24) is "OK"
• DC link is precharged
• Pulse enable (X21.3/.4) in effect
• No overtemperature
• No overcurrent tripping

For correct operation, this signal must be "interconnected" to the parameter

p864 ("Infeed operation") of every drive object.
Because the DRIVE-CLiQ connection is missing, this signal cannot be
interconnected directly to parameter p864; it first has to be wired to a digital
input of the CU or the TB30 (if available). This signal state is then available in
the parameter r722 (CU) or r4022 (TB30).
From there, the signal can be interconnected to parameter p864. The
interconnection is made via the expert list of the relevant drive object.

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Training Document 5 - 10 Line and motor modules booksize
Supply voltage The drive unit supply voltage of the relevant Line Module or Motor Module is
entered at parameter p210.

Line Module For the infeed:

p210: Rms value of the phase-to-phase line voltage
p3510: DC-link voltage setpoint
Default: p3510 = p210 * 1.5

Motor Module For the Motor Module:

p210: Rated value of the DC link voltage
This is used to calculate the monitors and limit values for the Vdc controller:
p1244: Upper DC link voltage threshold (Vdc_max)
p1248: Lower DC link voltage threshold (Vdc_min)

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Training Document 5 - 11 Line and motor modules booksize
Training case The Smart Line Module is adapted to the voltage in the office in the training
case:
• Instead of the usual 380 ... 480 V 3 AC the supply voltage is 230 V 1 AC, N
• Voltage monitoring has been changed
• Regenerative feedback is blocked

The limits must be moved further apart to allow the servo motors to be
accelerated or delayed with short ramps.
Important are:
• The limits of the Vdc controller: p1244, p1248,
• The rigid internal limits in relation to parameter p210

Limit Vdc_max Even though the unregulated DC link voltage on the training case assumes a
value around 320 V at Uline = 230 V, p210=380 V is parameterized.
This means that following recalculation, the internal upper limit will be raised
to 710 V.

Limit Vdc_min To achieve a low Vdc_min limit with this setting, the limit is reduced by 80 V via
parameter p278.

Rectification Despite this, with dynamic controller adjustment of the servo drives and
maximum acceleration from 0 to 6000 rpm, undervoltage can still occur for the
DC link and as a result of the only partially utilized diode rectifier also
inadmissible voltage dips.
The best remedy is usually to limit I max to 3 A.

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Training Document 5 - 12 Line and motor modules booksize
SITRAIN Page Course DR-S12-PM
Training Document 5 - 13 Line and motor modules booksize
Danger This means that there is a risk of an electric shock. Hazardous voltage is still
present for up to 5 minutes after the power supply has been switched off.
The protective cover must not be opened until this time has elapsed.
When opening the protective cover for the DC link, you must press the release
catch. Use a suitable tool (e.g. a screwdriver) for this.

Operation The components must only be operated when the protective cover of the DC
link is closed. Damaged components must not be operated further, otherwise
this could result in secondary damage or accidents.

Hazard warning The DC link discharge time hazard warning in the local language must be
attached to all of the components. A set of labels in 16 languages is provided
with the component.
If a 50 mm wide Motor Module or a DC link component of corresponding width
(e.g. Braking Module, Control Supply Module, Voltage Clamping Module) is
located at the left-hand end of the drive line-up, the DC link bridge (together with
the screws) must be removed.

Installation It is not permissible to insert the screws without a DC link bridge. For all other
power units and DC link components (e.g. Capacitor Module) that are wider
than 50 mm, the DC link bridge must be swiveled completely to the right and
tightened. It must not be moved to the left or removed.

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Training Document 5 - 14 Line and motor modules booksize
Multi-tier configuration Continuation of the DC link with the DC link adapter (installation above) external
to the components is achieved using single-core, finely-stranded and shielded
cables that are laid so as to ensure they are short-circuit and ground-fault proof.
The distance between the two module rows depends on the wiring and cable
cross-section:
• For modules with a width of between 50 and 100 mm, the distance between
the upper and lower module row must be at least 300 mm.
• For modules with a width of between 150 and 300 mm, the distance between
the upper and lower module row must be at least 500 mm.

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Training Document 5 - 15 Line and motor modules booksize
Capacitor Module The Capacitor Module is precharged by the Line Module. The applicable
maximum permissible DC link capacitances of the Line Modules must be taken
into account.
Voltage Clamping
Module Under certain unfavorable conditions, voltage rises can occur in extended drive
line-ups due to the stimulation of the system resonance frequency. This can be
particularly damaging for the insulation systems of the connected motors since
partial discharges can occur.
The Voltage Clamping Module ensures that the motor voltages are limited to
permissible values even when resonance occurs. In conjunction with an Active
Line Module with an HF line reactor the Voltage Clamping Module must always
be used if the total lengths of all the motor and DC link cables exceed the
following value:
- 350 m for shielded cables / 560 m for unshielded cables.
In conjunction with the Voltage Clamping Module, the following total cable
lengths are permitted:
- 630 m shielded cables / 850 m unshielded cables

Marginal conditions The following details also apply:

• Power derating for Line Modules to 80% for cable lengths > 350 m.
• Maximum step-up factor 1.4 to 1.6 (rectification factor Vdc link/Uline)
• No built-in motors can be connected (torque motors, linear motors)
• Can only be connected to TN line supply systems with grounded neutral
point.
• The EMC limit values (radio interference voltage) are no longer observed,
which means that special measures have to be taken to ensure CE
conformity (on-site measurement (subject to charge) and adjusted filter).

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Training Document 5 - 16 Line and motor modules booksize
Description The Control Supply Module (CSM) in booksize format provides a 24 V DC
power supply.
In normal operation the component obtains its supply from the line voltage.
In the event of a power failure, the component automatically changes over to
supply from the DC link.
This makes it possible, for example, to execute retraction movements in the
event of a failure of the line supply.
The Control Supply Module has safe electrical separation between the line and
the DC link potential. This means that there is no danger that the DC link will be
charged unintentionally. The Control Supply Module can therefore remain
connected to the supply if the Line Module is metallically separated from the
supply, for example via a line contactor.
The 24 V ground of the Control Supply Module is internally grounded.
The CSM has an internal line filter (Class A for TN systems) and the pre-
charging circuit for the DC link inside the unit, from which the isolated 24 V
supply is generated.
The CSM also features a current limitation function. When conductors of
2.5 mm2 in cross-section are used at operating temperatures up to 40 °C, no
additional protection or short-circuit-proof assignment of the cables is necessary
on the 24 V side.
If several branches are planned, it is recommended that a SITOP select
diagnostics module is used as overcurrent protection.

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Training Document 5 - 17 Line and motor modules booksize
Description Properties of Braking Modules and braking resistors:
• Conversion of DC link energy to heat loss in the external braking resistor
• As the Smart and Active Line Modules are feedback-capable, Braking
Modules and braking resistors are not required for normal operation.
• These components must only be provided if a machine has to be stopped
specifically in the event of a power failure (regenerative feedback mode no
longer possible).
• The Chassis Braking Module is built directly in to a Motor Module or Line
Module and does not require additional space in the control cabinet.

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Training Document 5 - 18 Line and motor modules booksize
SITRAIN Page Course DR-S12-PM
Training Document 5 - 19 Line and motor modules booksize
Motor Module A Motor Module is a power unit (inverter) that provides the power supply for the
connected motor(s). The power is supplied by the Infeed Module via the DC
link. A Motor Module must be connected to a Control Unit via DRIVE-CLiQ. The
open-loop and closed-loop control functions for the Motor Module are stored in
the Control Unit. One motor can be connected to the Single Motor Module and
two motors can be connected to the Double Motor Module.
Depending on the type (Single or Double), each Motor Module has one or two
DRIVE-CLiQ interfaces for connecting the motor encoder evaluation unit
(Sensor Modules). A Double Motor Module saves up to 50% space compared to
the Single Motor Modules.
The specified depth of 270 mm only applies to devices with air cooling. The
models with push-through cooling and cold plate cooling have a reduced
mounting depth.
All components in the SINAMICS S system are cULus approved. The cULus
mark is a test mark of Underwriters Laboratories (UL), an independent, non-
profit product safety certification organization in the USA and indicates
compliance with UL and CSA (Canadian Standard Association) standards.
Characteristics
• Compact design with high power density, particularly in the case of Double
Motor Modules
• Integrated DC link and 24 V DC busbar
• Short-circuit and ground-fault proof
• Integrated safety function, such as "Safe Torque Off“ (STO), "Safe Stop1“
(SS1) and "Safe Brake Control“ (SBC)
• Integrated motor brake connection and armature short-circuit brake
• Motor connection via connectors (up to 30 A) or bolts

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Training Document 5 - 20 Line and motor modules booksize
Note Cable shields and unused power cable conductors (e.g. brake conductors) must
be connected to PE potential to prevent capacitive cross-talk charges.
It is essential to apply the shield for the motor holding brake. Furthermore, only
Motion-Connect cables must be used for integrated motor holding brakes, as
otherwise insulation of the cores is not guaranteed. Risk of electric shock.
The temperature sensor connection is required for motors where the
temperature value is not transmitted via DRIVE-CLiQ. Cables to connect
temperature sensors must always be installed with shielding. The cable shield
must be connected to the ground potential at both ends over a large surface
area. Temperature sensor cables that are routed together with the motor cable
must be twisted in pairs and shielded separately.
A regulated DC power supply is required to operate motors with a built-in
holding brake. The power supply is realized via the internal 24 V busbars. The
voltage tolerances of the motor holding brakes and the voltage losses of the
cables must be taken into account.
If the "Safe Torque Off“, "Safe Stop1“ or "Safe Brake Control“ safety integrated
function is selected, the -X21:3 24 V DC and -X21:4 terminals must be
grounded for operation. Upon removal, pulse suppression is activated.

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Training Document 5 - 21 Line and motor modules booksize
Learning Targets .............................................................................................................................. 2
Control and status words .................................................................................................................. 3
Control word and status word ........................................................................................................... 4
Control logic ..................................................................................................................................... 8
Speed setpoint ................................................................................................................................. 10
Programming signal links ................................................................................................................. 11
Diagnostics using parameters .......................................................................................................... 16
Trace function .................................................................................................................................. 18
Exercise 1: Enable signals ............................................................................................................... 25
Exercise 2: Control via terminal signals ............................................................................................ 26
Exercise 3: Tracing the signals ......................................................................................................... 31

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Training Document 6-1 Control word setpoint and device trace
SITRAIN Page Course DR-S12-PM
Training Document 6-2 Control word setpoint and device trace
Communication To execute functions, the drive object requires enable signals and a speed
setpoint. The enable signals are connected via the control word. Feedback
signals from the drive object are output via the status word.
In this way, the control word (STW1) and the status word (ZW 1) form the
command interface between the controller and the drive.

Control word The control word is a group of 16 internal binary signals that must be provided
for controlling the internal sequence control/inverter. In order to move the drive,
the control word must be connected via the sequence control.
The control word corresponds to the PROFIdrive profile standard.

Status word The status word is a group of 16 internal binary signals that must be provided
for controlling the internal sequence control / inverter. The control word (Bit 0-
10) corresponds to the PROFIdrive standard profile.

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Training Document 6-3 Control word setpoint and device trace
Control word The control word is a group of 16 binary signals that must be provided to the
internal sequence control / closed-loop control of the converter. If the converter
and SIMATIC S7 are connected to each other via PROFIBUS or PROFINET,
the control word can be provided by a higher-level output word.

ON/OFF1 An edge change is required to switch on and OFF2 and OFF3 must not be
active. When switching off the motor brakes on the down ramp of the ramp-
function generator and the converter then switches off.

OFF2 The motor coasts to a standstill without braking and the converter shuts down
immediately.

OFF3 The motor brakes with the return edge of the OFF3 signal. The converter
remains switched on.

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Training Document 6-4 Control word setpoint and device trace
Status word The status word is a group of 16 binary signals that are provided from the
internal sequence control / closed-loop control of the converter.
If the converter and SIMATIC S7 are connected to each other via PROFIBUS,
the status word can be monitored and analyzed by a higher-level input word.

Switch-on inhibit This status is reached when the error is remedied and a drive fault is
acknowledged. A subsequent restart is only possible through OFF1 followed
by ON.

Alarm, fault General fault (bit 3)

General alarm (bit 7)

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Training Document 6-5 Control word setpoint and device trace
SITRAIN Page Course DR-S12-PM
Training Document 6-6 Control word setpoint and device trace
 The reactions to the signals are as follows:

OFF1 The drive is braked by immediately entering n_set = 0 along the ramp-function
generator down ramp (p1121).
Once standstill is detected, any configured motor holding brake is closed
(p1215). The pulses are suppressed when the brake application time (p1217)
expires. Zero speed is detected when the actual speed value is less than the
speed threshold (p1226) or when the monitoring time (p1227) that started when
speed setpoint ≤ speed threshold (p1226) has expired.

OFF2 Immediate pulse suppression, the drive coasts to standstill.

• Any parameterized motor holding brake is closed immediately.
• The switch-on inhibit is activated.

OFF3 The drive is braked immediately by entering n_set = 0 along the OFF3 down
ramp (p1135).
• When zero speed is detected, the motor holding brake (if parameterized) is
closed. The pulses are suppressed when the closing time of the holding
brake (p1217) expires. Zero speed is detected when the actual speed value
is less than the speed threshold (p1226) or when the monitoring time
(p1227) that started when speed setpoint ≤ speed threshold (p1226) has
expired.
• The switch-on inhibit is activated.

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Training Document 6-7 Control word setpoint and device trace
 Auf die Signale erfolgen diese Reaktionen:

AUS1 Der Antrieb wird durch sofortige Vorgabe von n_soll = 0 an der Hochlaufgeber-
Rücklauframpe (p1121) abgebremst.
Nach Erkennen des Stillstands wird eine eventuell parametrierte
Motorhaltebremse geschlossen (p1215). Nach Ablauf der Schließzeit (p1217)
werden die Impulse gelöscht. Stillstand wird erkannt, wenn der Drehzahlistwert
die Drehzahlschwelle (p1226) unterschreitet oder wenn die bei Drehzahlsollwert
≤ Drehzahlschwelle (p1226) gestartete Überwachungszeit (p1227) abgelaufen
ist.

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Training Document 6-8 Control word setpoint and device trace
 Auf die Signale erfolgen diese Reaktionen:

AUS2 Sofortige Impulslöschung, der Antrieb trudelt aus.

• Eine eventuell parametrierte Motorhaltebremse wird sofort geschlossen.
• Die Einschaltsperre wird aktiviert.

AUS3 Der Antrieb wird durch sofortige Vorgabe von n_soll = 0 an der AUS3-
Rücklauframpe (p1135) abgebremst.
• Nach Erkennen des Stillstandes wird eine eventuell parametrierte
Motorhaltebremse geschlossen. Am Ende der Schließzeit der Haltebremse
(p1217) werden die Impulse gelöscht. Stillstand wird erkannt, wenn der
Drehzahlistwert die Drehzahlschwelle (p1226) unterschreitet oder wenn die
bei Drehzahlsollwert ≤ Drehzahlschwelle (p1226) gestartete
Überwachungszeit (p1227) abgelaufen ist.
• Die Einschaltsperre wird aktiviert.

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Training Document 6-9 Control word setpoint and device trace
 In addition to the control word and status word for sequence control, the drive
objects have numerous other control words and status words, such as:
• Control word fault/alarm
• Control word, speed controller
• Control word, setpoint channel
• Control word encoder 1, 2, 3
• Control word command data set CDS selection
• Status word faults/alarms 1
• Status word faults/alarms 2
• Status word, speed controller
• Status word monitoring 1, 2, 3
• Status word encoder 1, 2, 3
• Status word closed-loop control
• Missing enables
• Status word ramp-function generator
• Status word Safety Integrated Control Unit
• Status word Safety Integrated Motor Module
• Status word Safety Integrated Control Unit and Motor Module

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Training Document 6 - 10 Control word setpoint and device trace
Status words Via
>> Drive -> Control logic
It’s possible to display the states of the individual signals of the status word.
The selection menu allows you to display various status words.

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Training Document 6 - 11 Control word setpoint and device trace
Speed setpoint Besides specifying the control signals, a specified speed is also required for the
drive by the application. The speed is specified in STARTER via the"Setpoint
addition" screen which can be selected via the "Open-loop/closed-loop control“
directory in the drive.
Two speed setpoints can be specified in this screen. These speeds are
processed further in the controller and converted to a pulse pattern to control
the motor.

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Training Document 6 - 12 Control word setpoint and device trace
BICO technology Each drive unit contains a large number of interconnectable input and output
variables as well as internal control variables. Using BICO (BInector COnnector)
technology allows the drive to be adapted to a wide variety of conditions.
Binary and analog signals, which can be connected freely by means of BICO
parameters, are identified by the prefix BI, BO, CI or CO in their parameter
name. These parameters are identified accordingly in the parameter list or in the
function diagrams.

Binectors Binectors are binary signals that can be interconnected as required

(BO = Binector Output). They represent one bit of a "BO display parameter"
(e.g. bit 15 of r0723).

Connectors Connectors are "analog signals" that can be interconnected as required

(e.g. percentages, speeds). Connectors are also display parameters
(CO = Connector Output).
A CO (Connector Output) can also serve as a write parameter, e.g. p2900 fixed
value 1 [%]. In this way, for example, parameters from an external device can
be provided with values, and then used as a data source in a BICO
interconnection.

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Training Document 6 - 13 Control word setpoint and device trace
BICO colors Different colors are assigned to the parameters, connectors and binectors in the
STARTER expert list:
BI (Binector Input): light blue
BO (Binector Output): yellow
CI (Connector Input): dark blue
CO (Connector Output): yellow, if read-only parameters
CO (Connector Output): green, if fixed-value parameter

BICO symbols Different BICO symbols are used in the function diagrams
• Round symbols for binectors
• Square symbols for binectors

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Training Document 6 - 14 Control word setpoint and device trace
Terminal evaluation This selection evaluates a level at the corresponding digital input. This means:
• 24 V corresponds to logical "1"
• 0 V corresponds to logical "0"

Simulation mode Digital inputs can be operated in simulation mode. This allows the logical
relationship between these signals and their further connections to be tested.

Note Inputs can be switched to simulation mode only when they are in online mode
Switching to offline does not exit simulation mode!

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Training Document 6 - 15 Control word setpoint and device trace
 Using the graphical menus, BICO interconnections can be implemented from
the source to the target, as well as from the target to the source. The same
source parameter (here: TB30: r4055.0) can be connected to several target
parameters.
If a source parameter is connected to a previously connected target parameter,
Starter will detect this and output the following message:
"Remove existing connection?"

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Training Document 6 - 16 Control word setpoint and device trace
 BICO interconnections can also be implemented within the expert list. Since a
BICO interconnection is possible there from the target to the source, the
following procedure must be considered:

1. Search for the target parameter in the object-specific expert list

(here: p1075)

2. Select the drive object here with the required source parameter
(here: TB30: r4055.0)

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Training Document 6 - 17 Control word setpoint and device trace
 In online mode, the "Control word sequence control" and "Status word sequence
control" are displayed here. A green LED represents a "1" signal and a gray
LED represents a "0" signal.
Apart from these two words, depending on the enabled functionality, status and
control words for faults and alarms, speed controller, encoder, basic positioner,
etc. will be available.

Missing enables The missing enables of the respective drive object are displayed here. An
orange LED means that the associated enable bit has not yet been set.

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Training Document 6 - 18 Control word setpoint and device trace
Missing enables The missing enables of the respective drive object are displayed here.
An orange LED means that the associated enable bit has not yet been set.
Comprehensive help with information about the reason for the missing enable
can be accessed in Starter via the button

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Training Document 6 - 19 Control word setpoint and device trace
Trace function A trace is used to record signals over a period of time. STARTER allows eight
signals each to be traced using two device traces. A trigger signal can be used
to start tracing. The traced characteristic curves can be saved as a graphic or
as a value file.

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Training Document 6 - 20 Control word setpoint and device trace
Trace The trace is a graphical tool for recording signals. Teher eare two traces Trace
1 and Trace 2. For each trace (8 signals can be recorded.
The signals are selected line by line by selecting the drive object and in it, the
required parameter.

Recording The trace signals are output typically in the current controller clock cycle or in a
multiple thereof (trace clock cycle) that is set via the "Factor". This means that a
finite recording time can be specified in the trace memory on the Control Unit.
With this setting, a trace can be activated and recorded without an online
connection for reading in later online. If an endless trace is selected, recording
will continue until the trace function is stopped. An uninterrupted online
connection is required to do this, since the main memory of the PG is used as
the trace memory.

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Training Document 6 - 21 Control word setpoint and device trace
Trigger This is used to specify the signal and, where applicable, the binary signal that
will start the trace.
When binary signals are used as trigger conditions, it is also necessary to mask
the required bit and its level.
A pretrigger time can also be defined.

Display options Additional settings can be made here for signal display. It is advisable to select
"Repeated measurement" when the signals are scaled. These settings will then
be available for all further measurements.

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Training Document 6 - 22 Control word setpoint and device trace
Scaling In the standard setting for the trace, the recorded signals are presented in the
full screen height. If more than one signal with the same physical variable is
recorded, such as speed setpoint and actual speed value, actual value over-
shoots may cause a scaling difference in the y-axis. To ensure comparability,
the function "scaling" can be used to adapt the grid for one signal to that of the
other signal.
In the example here, "Curve 4.1" (speed setpoint) is scaled in the y direction in
the same manner as "Curve 4.2" (speed actual value). To ensure that this
setting is also available for the next measurement, the function "Repeated
measurement" must be activated in the trace settings.

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Training Document 6 - 23 Control word setpoint and device trace
Bit tracks The device trace allows the status of the individual bits to be traced.
The procedure is as follows:

1. Select signal that contains the bit to be traced,

e.g. r898 (control word of the sequence control)

2. Select the "Select bit tracks" button. In the "Parameterization of bit tracks"
table, select the signal word and enter the bit signal to be traced in the "Bit"
column.

3. Start the trace.

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Training Document 6 - 24 Control word setpoint and device trace
Write recording
to device This is where you activate automatic storage of measurements. The trigger is
activated automatically again at the end of a recording if the Number of
recordings is greater than zero. The measurements are written to the memory
card in directory /USER/SINAMICS/DATA/TRACE as ACX files.
If Copy RAM to ROM has been activated during the download of the
parameterization, the activation is also retained after restarting the controller.
This setting is only possible for a time-limited trace.
You can either read out the measurements with a card reader via the Web
server. In Trace, on the Measurements tab, select the ACX data you have read
out with the Open measurements button.

Note The recorded ACX files contain less information than TRC files. The following
information is omitted from ACX files:
Designation of the object
Parameter information (read/write parameters, number of indices)
Units of measurement
If applicable, use the comment field on the Measurements tab to add this
information.

number of recordings After activating Write recording to device this is where you set the number of
recordings. The size of the ring buffer depends on the device and is
dimensioned for at least five measurements.

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Training Document 6 - 25 Control word setpoint and device trace
Safety information Please note that:
• The course instructions have been produced for:
 A course held by a course leader
 Activities carried out on special training equipment
• The training equipment is operated under laboratory conditions.
In case of doubt, always ask your course leader – particularly when handling
components that carry electrical current or which can move.
• When carrying out work on equipment, the safety information in the
associated product documentation must always be observed!
The training documents alone are not sufficient.

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Training Document 6 - 26 Control word setpoint and device trace
Task The two drives should first be traversed using the control panel. Open your
"S120_Servo_1" project and go online.

1. Open the control panel.

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Training Document 6 - 27 Control word setpoint and device trace
 2. The diagnostic area should now also be shown.
The "Diagnostics" button opens a further screen that shows the missing
enables.

Which signals are missing?

………………………………………………………………………………

Use the "Assume control priority" button to traverse the drive via the control
panel.
Which missing signals are now shown?

………………………………………………………………………………

Set the enables in the "Enables" selection field.

Which missing signals are now shown?

………………………………………………………………………………

Start the drive using the green button.

Which missing signals are now shown?

………………………………………………………………………………

How does the drive respond to the enable signal?

………………………………………………………………………………

Enter a setpoint of 100 rpm and start the drive. Stop the drive and return the
control priority.

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Training Document 6 - 28 Control word setpoint and device trace
Starting basis The two drives should no longer be traversed via the control panel, but via the
operator box. In addition to the control signals, a speed setpoint must also be
specified for the two drives.

Task After configuring the Servo_02 and Servo_03 drives, most of the control signals
for operating the drives are already pre-assigned "1". Now change the pre-
assignment of the control word of the sequence control, so that you can control
the drives via the operator box:

1. To do this, select
>> Drives > Servo_02 > Control logic
There, you can further assign the control signals in a very straightforward
and transparent way, without having to open the expert list.

2. Select the "Control word sequence control".

3. Connect the ON/OFF1 signal to switch 0:

>> p840[0] = CU_S_004: DI 0 = r722.0
 SERVO_02, p0840[0] BI : ON/OFF1 = CU_S_004, r0722: Bit 0

4. Parameterize the OFF2 signal to switch 1 on the operator box:

………………………………………………………………………………

5. Parameterize the OFF3 signal to switch 2 on the operator box:

………………………………………………………………………………

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Training Document 6 - 29 Control word setpoint and device trace
Task Also change the pre-assignment of the "Control word faults/alarms", so that you
can acknowledge faults using the operator box.
Select analog input AI 0 of the operator box as speed setpoint source:

1. Select the "Control word faults/alarms".

2. Connect the signal "1. Acknowledge faults" to switch 3 of the operator box:

………………………………………………………………………………

3. Is analog input AI 0 interconnected corresponding to the factory setting?

………………………………………………………………………………

4. Interconnect the setpoint source "speed setpoint 1" to potentiometer AI 0 of

the operator box. To do this, open the screen form:
>> Drives > Servo_02 > Open-loop/closed-loop control > Setpoint addition
SERVO_02, p1155[0] CI : Speed setpoint 1 = TB30_04, r4055[0]

5. Start the SERVO_02 drive using the operator box and specify the speed
using potentiometer AI 0.

6. Monitor the online values in the "Control logic" and "Setpoint addition" screen
forms.

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Training Document 6 - 30 Control word setpoint and device trace
Task For SERVO_03, establish the corresponding BICO interconnections starting
from the input terminals:

1. In the project navigator

>> CU_S_004 > Inputs/outputs > Isolated digital inputs

2. Use digital inputs DI 4 .. 7 (X132) to control SERVO_03:

DI 4 ON/OFF1:

………………………………………………………………………………
DI 5 OFF2:

………………………………………………………………………………
DI 6 OFF3:

………………………………………………………………………………
DI 7 1. Acknowledge faults:

………………………………………………………………………………

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Training Document 6 - 31 Control word setpoint and device trace
 3. In the project navigator, open
>> CU_S_004 > TB30_04 > Inputs/outputs > Analog inputs

4. Assign the parameters for analog input AI 1 (Terminals X482: 3/4) to enter
the speed setpoint for SERVO_03:
AI 1 n_set:

………………………………………………………………………………

5. Check the scaling of the analog input.

The scaling defines the assignment between the voltage and
a percentage value.
In our example:
-10V corresponds to -100%
10 V corresponds to 100%
This means that no absolute value is assigned to the voltage; rather,
a percentage value that is converted to an absolute value using the
corresponding reference value.

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Training Document 6 - 32 Control word setpoint and device trace
Task Test the switch-on and switch-off behavior of both drives based on the following
diagram.

1. Set the switches for OFF2 and OFF3 to "1", before you start the drive with a
rising edge at the ON/OFF1 signal

2. Now set the ON/OFF1 signal back to "0".

3. Switch on the drive again, and this time set signal OFF2 to "0" and monitor
the response.

4. Switch on the drive again, and this time set the OFF3 signal to "0" and
monitor the response.
What difference did you notice?

………………………………………………………………………………

5. Once you have completed the test, save the online changes to the CF card
(ROM), to the PG and to the hard disk.

6. This tested project is used as the starting point for further exercises.
Therefore archive the project.

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Training Document 6 - 33 Control word setpoint and device trace
Task Use the trace to record the speed setpoint, actual speed value and actual
current value in a defined period
Make the settings to trace the speed setpoint, speed actual value and current
actual value using the trace function:

1. Open the trace:

>> Drives > SERVO_02 > Commissioning > Device trace
2. Parameterize trace 1 for the following signals:
• Speed setpoint after the filter (r62)
• Speed actual value (r63)
• Current actual value (r68)
3. Select for recording:
• Measured-value acquisition: time-limited trace
• Recording duration: 6 seconds (6000 ms)
Possibly with the entered recording duration displayed in red. To do this,
activate the arrow key "Trace cycle clock" to automatically align the trace
cycle clock to the size of the measured value memory. The recording
time is then displayed in black.
4. Define the trigger:
• Type: Trigger on variable – Positive edge
• Parameter no./variable: Servo_02, speed setpoint (r62)
• Threshold value 0,1 rpm
• Pretrigger: 100 ms
5. Select as display options:
• Repeated measurement

Note If the parameterization is realized offline, then it must still be transferred to the
drive (the parameterization is downloaded).

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Training Document 6 - 34 Control word setpoint and device trace
Task Record a trace:

1. Enter a speed setpoint of nset < 1000 rpm.

2. Start trace 1 using the "Triangular" button.

3. Monitor the feedback "Trace 1 waiting for trigger".

4. Switch on the drive.

5. Increase the speed setpoint.

6. Monitor the feedback "Trace 1 in progress".

7. After completion of the recording and data transfer to the PC, the signals are
displayed.

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Training Document 6 - 35 Control word setpoint and device trace
Task Test some of the options for post processing the signals:

1. Select the "Time diagram“ tab.

• The axis labeling is assigned when a signal name is selected.
• When the axis labeling is selected, the signal can be shifted in the y
direction.
• >> using the right mouse key > Scaling
scale the speed setpoint (r62) just like the speed actual value (r63).
• By selecting a signal section (with the left mouse key pressed), the size
of a signal section can be increased.
• With the right-hand mouse key
 the zoom factor can be reduced or undone
 measurement cursors for time and amplitude axes can be displayed
 the trigger line can be displayed.

2. Select the "Trace time diagram“ tab at the bottom of the screen.
• Under "Display", signals can be shown or hidden in the time diagram.
• Under "Comment", the signal name can be changed.

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Training Document 6 - 36 Control word setpoint and device trace
Task Record the selected bit tracks while the drive is being switched on.

1. Add two signals to the trace:

• Control word of the sequence control (r0898)
• Status word of the sequence control (r0899)

2. Select the bit tracks icon.

3. Select the signal and bit to be traced from the table:

• Servo_02.r0898 Bit 0 On/Off1
• Servo_02.r0898 Bit 1 OC/Off2
• Servo_02.r0898 Bit 2 OC/Off3
• Servo_02.r0899 Bit 1 Ready for switch on
• Servo_02.r0899 Bit 2 Ready
• Servo_02.r0899 Bit 3 operation enabled

4. Start the trace.

5. Switch on the drive using the operator box

(not using the control panel or function generator).

6. Monitor the recorded signals.

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Training Document 6 - 37 Control word setpoint and device trace
Learning Targets .............................................................................................................................. 2
DRIVE-CLiQ .................................................................................................................................... 3
DRIVE-CLiQ Hub ............................................................................................................................. 8
DRIVE-CLiQ rating plates ................................................................................................................ 10
Topology .......................................................................................................................................... 12
Module replacement ......................................................................................................................... 18
Firmware update .............................................................................................................................. 23
Encoder connection ......................................................................................................................... 24
Encoder ........................................................................................................................................... 25
Gebertypen ...................................................................................................................................... 26
Encoder replacement ...................................................................................................................... 27
Exercise 1: Topology error – incorrect port ....................................................................................... 30
Exercise 2: Topology error – component is missing .......................................................................... 33
Exercise 3: Deactivating/activating components ............................................................................... 35
Exercise 4: Deactivating/activating objects ....................................................................................... 36
Exercise 5: CompactFlash card ........................................................................................................ 37
Exercise 6 (optional): Replacing a motor .......................................................................................... 40
Exercise 7 (optional): Conversion to DQI motor ................................................................................ 42

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Training Document 7-1 Topology
SITRAIN Page Course DR-S12-PM
Training Document 7-2 Topology
DRIVE-CLiQ DRIVE-CLiQ is the digital interface between SINAMICS components
The SINAMICS S120 components, including the motors and encoders, are
interconnected via a joint serial interface called DRIVE-CLiQ.
All communication-capable components have one or more ports for the
DRIVE-CLiQ cables.
The communication is based on Ethernet technology with 100 Mbit/s.

Topology The topology describes the ports used to connect the components.

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Training Document 7-3 Topology
Cable The standardized form of the cable and plug engineering reduces the range of
parts and storage costs.

Plug-in connectors The DRIVE-CLiQ plug-in connections forward the 24 V DC voltage to the
encoder supply via two additional contacts.
Encoder evaluations are available for third-party motors or retrofit applications
for converting standard encoder signals to DRIVE-CLiQ.

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Training Document 7-4 Topology
Line topology The components are arranged in a line provided that this does not violate any
DRIVE-CLiQ rules.

Tree topology The components are connected in separate branches originating from the CU.
If components are deactivated, in order to remove components from the
machine, for example, this can only be done for components at the end of the
branch.
If components are deactivated within a line, the components that follow in the
line can also no longer be accessed.

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Training Document 7-5 Topology
DRIVE-CLiQ rules A comprehensive set of rules apply for wiring components with DRIVE-CLiQ.
Some of the most important rules are listed below:
• The following applies for booksize format:
 In the servo and vector U/f control modes, only one Line Module may be
connected to the Control Unit. In the vector mode, a maximum of three
further Line Modules may be connected in parallel (i.e. a total of 4 Line
Modules).
 In the servo mode, Line Modules and Motor Modules can be connected to
the same DRIVE-CLiQ line.
 In the vector mode, the Line Modules and Motor Modules must be
connected to separate DRIVE-CLiQ lines.
• The following applies for chassis format:
 Line Modules (Active Line, Basic Line, Smart Line) and Motor Modules
must be connected to separate DRIVE-CLiQ lines.
 Motor Modules with different pulse frequencies (frame sizes F, G, H, J)
must be connected to separate DRIVE-CLiQ lines.
• The sampling times p0115[0] (p4099 for TM) of all components that are
connected to a DRIVE-CLiQ line must be divisible by one another with an
integer result.
The sampling time corresponds to the current control cycle for a drive object.
The further cycles such as speed controller cycle, setpoint channel, position
controller cycle, etc. can be configured at the drive object.

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Training Document 7-6 Topology
Recommended rules The following rules should be observed to ensure reliable operation:
• The DRIVE-CLiQ cable from the Control Unit should be connected to X200
on the first booksize power unit or X400 on the first chassis power unit.
• The DRIVE-CLiQ connections between the power units must each be
connected from interface X201 to X200 and/or from X401 to X400 on the
follow-on component.
• A single Line Module should be connected directly to the X100 DRIVE-CLiQ
socket of the Control Unit.
• Several Line Modules should be connected in a line.
• If the X100 DRIVE-CLiQ socket is not available, the next higher DRIVE-CLiQ
socket should be used.
• The motor encoder should be connected to the associated power unit.
• The motor encoder for the first drive of a Double Motor Module should be
connected to the associated DRIVE-CLiQ socket X202.
• The motor encoder for the second drive of a Double Motor Module should be
connected to the associated DRIVE-CLiQ socket X203.
• Only one final node should ever be connected to free DRIVE-CLiQ ports of
components within a DRIVE-CLiQ line (e.g. Motor Modules wired in series),
e.g. one Sensor Module or one Terminal Module without forwarding to
additional components.
• If possible, Terminal / Sensor Modules of direct measuring systems should
not be connected to the DRIVE-CLiQ line of Motor Modules but rather to free
DRIVE-CLiQ ports of the Control Unit.

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Training Document 7-7 Topology
DMC20, DME20 The DMC20 and DME20 DRIVE-CLiQ Hub Modules are used to implement the
point-to-point distribution of a DRIVE-CLiQ line. It is possible to connect two
DRIVE-CLiQ Hub Modules in series (cascade connection).
With the DMC20/DME20, an axis grouping can be expanded by 4 DRIVE-CLiQ
sockets for additional subgroups.
The component is ideal for applications which require DRIVE-CLiQ nodes to be
removed in groups, without interrupting the DRIVE-CLiQ line and, therefore,
data exchange.

Interfaces DMC20 The DMC20 DRIVE-CLiQ Hub Module in degree of protection IP20 is designed
for mounting in control cabinets.
The following are located on the DMC20 DRIVE-CLiQ Hub Module:
• 6 DRIVE-CLiQ sockets for connecting 5 DRIVE-CLiQ nodes
The status of the DMC20 DRIVE-CLiQ Hub Module is indicated via a multi-color
LED.

Interfaces DME20 The DME20 DRIVE-CLiQ Hub Module in degree of protection IP67 is designed
for mounting outside control cabinets.
The following are located on the DME20 DRIVE-CLiQ Hub Module:
• 6 DRIVE-CLiQ sockets for connecting 5 DRIVE-CLiQ nodes

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Training Document 7-8 Topology
Adding a
DRIVE-CLiQ Hub The DRIVE-CLiQ Hub is added in the "Topology" screen. Then, the components
can be connected to the ports.
The hub occupies two component numbers. It is not an autonomous drive object
and does not have to be configured.

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Training Document 7-9 Topology
Rating plate All DRIVE-CLiQ components have a separate electronic rating plate:
• This electronic rating plate contains all the relevant technical data about that
particular component.
• For motors, for example, these data include the parameters of the electric
equivalent circuit diagram, the current controller data and characteristic
values for the built-in motor encoder. These data are automatically read via
DRIVE-CLiQ by the Control Unit and need not be input during
commissioning or after a component is exchanged.
• In addition to the technical data, the rating plate includes logistical data
(manufacturer ID, order number, and globally unique ID).
• Since these values can be read electronically both on site and also by
remote diagnostics, unambiguous identification of all components used in a
machine can be performed at any time, thus simplifying service.

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Training Document 7 - 10 Topology
Overview Information about the individual components of the drive system is displayed in
the "Overview" dialog in the "Version overview" tab.
In online mode, in addition to the components, the component number, Order
No., hardware version and serial number are displayed as well as the firmware
versions of the individual DRIVE-CLiQ components in particular after clicking on
the "Update topology" button.
For the correct functioning of the DRIVE-CLiQ communication, all components
must have the same firmware version as the Control Unit.

Version overview In this window, information about the individual components of the drive system
is displayed. On the basis of this information, the components can be clearly
identified. A firmware update can also be activated from the CF card.
• Component: Name of the drive component
• No.: Component number
• FW version: Firmware version of the drive component
• Order no.: Order number of the drive component in short form
• HW version: Hardware version of the drive component
• Serial No.: Serial number of the drive component.

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Training Document 7 - 11 Topology
Structure The topology is shown as a wiring tree. The Control Unit is the first element of
the tree. All components are attached to the CU. The terminal designations can
be picked off via the tooltip.

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Training Document 7 - 12 Topology
Project set topology The project set topology corresponds to the topology of the offline project.

Specified topology The target (specified) topology is stored on the CompactFlash card in the
Control Unit and is loaded to RAM during power-up of the Control Unit and then
compared to the actual topology.
The set topology can be specified in two ways and saved on the CompactFlash
card:
• Via STARTER by creating the offline configuration and then loading it to the
drive unit
• Via quick commissioning (automatic configuration) by reading the actual
topology and writing as set topology to the CompactFlash card.

Actual topology The actual topology is the DRIVE-CLiQ hardware wiring that is actually used.
When the drive system components are started up, the actual topology is
detected automatically via DRIVE-CLiQ.

Monitoring When the supply voltage is turned on, the actual topology is compared with the
set topology. Comparing the topologies prevents a component from being
controlled/evaluated incorrectly (e.g. drive 1 and 2).
When the drive system is started, the Control Unit compares the detected actual
topology and the electronic rating plates with the set topology stored on the
CF card.
If, during the startup, components are detected that cannot be assigned to any
configured component, they will be displayed in the actual topology with
component numbers greater than 200.

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Training Document 7 - 13 Topology
Comparison The topology view can also be used to compare two different topologies:
• Project set with specified
• Project set with actual
• Specified with actual

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Training Document 7 - 14 Topology
Change If differences are present in the topology (i.e. differences in the set/actual
interconnection), the user can compare the project set topology (offline
topology) and the set topology (topology on the memory card of the drive) with
the actual topology (actual interconnections).
Should there be differences in the topology, the project set topology can also be
changed by moving the required drive objects with drag-and-drop to the
required DRIVE-CLiQ interfaces.

Topology error A topology error always occurs when the configured interconnection information
and the actual interconnection differ.
Topology errors must be remedied. Otherwise, the configured drive objects will
not operate properly. A topology error is displayed with an appropriate error
message in the Alarm window.
Timestamp and
logical analysis In most cases, the system will generate several alarms when a fault occurs,
since the fault may have a variety of effects.
For example: The DRIVE-CLiQ cable to the Sensor Module of the
"Transport_blue" drive " has been removed.
Decisive in this case is the alarm A01482 Topology: Comparison Sensor
Module missing in the actual topology. However, in the case of the error
message F07016 Drive: Motor temperature sensor fault error message is only a
secondary error message.

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Training Document 7 - 15 Topology
Message Alarm A01382 Topology: Comparison Sensor Module shifted.

Cause The topology comparison has detected a shifted Sensor Module in the actual
topology compared to the set topology.
Startup of the drive system is halted. In this state, the drive control cannot be
enabled.

Remedy Adapt the topology:

• To undo the change to the actual topology, change the DRIVE-CLiQ cables.
• Commissioning software: Go online, perform an upload of the drive unit,
adapt the topology offline and perform a download of the modified project.
• Rectify topology fault automatically (p9904 = 1):
 Accept the actual topology in the set topology

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Training Document 7 - 16 Topology
Comparison quality When comparing the set and the actual topology and when replacing a module,
the configured comparison quality is used. The data of the electronic rating plate
stored in the module are used.
The electronic rating plate contains the following information:
• Component class (e.g. Sensor Module or Motor Module)
• Component type (e.g. "SMC20")
• Order No. (e.g. "6SL3055-0AA0-5BA0")
• Manufacturer (e.g. SIEMENS)
• Hardware version (e.g. A)
• Serial number (e.g. "T-P30050495")
The comparison quality is divided into the following levels:
High: Compares the entire electronic rating plate including
serial number
Medium: Compares the component type and the order number
Low: Compares the component type
Minimum: Compares the component class
The comparison quality can be set in the window of the set topology via the
shortcut menu (right-click) of the desired component. The comparison quality is
saved in the parameter CU: p9908.

Example If the "Medium" comparison quality is set for the input module, the module can
be replaced by a new module with the same order number without an error
message being issued. A difference is also not displayed in the topology
comparison.

Note The default setting of the comparison quality is "High". The comparison of the
serial number must be activated by additionally setting parameter p9909 = 0
however.

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Training Document 7 - 17 Topology
Replacement If the topology comparison for component replacement is active
(CU: p9909 = 1), safety considerations rule out swapping of two components in
an existing topology, for example to prevent unintentional wrong connection of
DRIVE-CLiQ cable or motor cables in the case of a false diagnosis.

CU parameter: p9909 Topology comparison, component replacement

CU: p9909 = 1 automatically adopts the serial number and the hardware version
of the newly replaced component from the actual topology to the set topology
and stores it in non-volatile memory.
For the exchanged components, the following data on the electronic rating plate
must match:
• Component type (e.g. "SMC20")
• Order No. (e.g. "6SL3055-0AA0-5BA0")
For CU: p9909 = 0, the serial number and hardware version are not adopted
automatically and an error message is generated.
Acceptance must be carried out via CU: p9905 = 1.

Series commissioning Irrespective of the parameter assignment CU: p9909 (= 1 / = 0), the serial
number of the hardware (actual topology) is accepted in the specified topology
after downloading a project from the PG/PC.

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Training Document 7 - 18 Topology
CU: p9904 If only one fault occurred during the comparison of the actual topology and the
set topology that can be acknowledged, this parameter can be used to start a
new comparison with acknowledgment of the fault in the set topology.
Acknowledgeable differences:
• Topology comparison, component shifted
• Topology comparison shows one component that has a different serial
number
• Topology comparison shows one component that is connected differently

CU: p9905 With CU: p9905 = 1, the serial numbers and the hardware versions of all
components in the actual topology are accepted in the specified topology and a
new comparison started.
For this device specialization, the components of the set topology may differ
from those of the actual topology only in the serial numbers.
With CU: p9905 = 2, the serial numbers, the hardware versions and the order
numbers of all components in the actual topology are accepted in the specified
topology and a new comparison started.
For this device specialization, the components of the speciified topology may
differ from those of the actual topology only in the serial numbers and order
numbers.

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Training Document 7 - 19 Topology
Different
serial number If a different serial number was determined when the drive unit was started, an
alarm is issued. Startup of the drive system is halted. In this case, the drive
control will not be enabled.
The following error message is issued:
Alarm: A01425 Topology: Comparison serial number of a component is different

Remedy Adapt the topologies:

• Change the actual topology to match the set topology.
• Load the actual topology that matches the set topology (commissioning
software).
 Acknowledgeable via
CU: p9904 or CU: p9905.
 Acknowledgeable via
CU: p9905 and can be deactivated via CU: p9906 or
CU: p9907/p9908.

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Training Document 7 - 20 Topology
Overview The procedure for the replacement of a DRIVE-CLiQ component depends
principally on whether or not the new component has a different order number.
If the order number is identical, after the replacement, it suffices to transfer the
data from the electronic rating plate of the component to the specified
configuration.
If the order numbers differ, the STARTER project must be modified
appropriately and then downloaded to the target device.
Replacement with
same order number The replacement of a component with the same order number generally
requires no tool support, if:
• The serial number of the new replacement component is not contained in the
stored specified topology of the Control Unit.
• Topology comparison component replacement active CU: p9909 = 1.
With this setting, during the startup, the new serial number of the spare part
is automatically transferred from the actual topology to the target (specified)
topology and saved in the non-volatile memory. The last or last two digits of
the order number (depending on the component type) are not checked, as
the HW version, for example, is encoded in these positions.
This mechanism is also suitable when several components are replaced.

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Training Document 7 - 21 Topology
 A PG with the STARTER software loaded is always required to replace a
DRIVE-CLiQ component with different order numbers, e.g. Motor Modules with
different power ratings.

Procedure For the replacement of a component with a different order number, proceed as
follows:

1. Switch off the power supply, remove the defective component and install the
new component. Ensure that the correct wiring is made (information is
contained in the appropriate manuals).

2. Switch the power supply on again. After the system startup, the alarm
"A01420 Topology: Comparison one component is different" will be
displayed.

3. Establish with the STARTER an online connection to the SINAMICS,

download the SINAMICS project data to the PG and store the data on the
hard disk.

4. Reconfigure the affected drive. Select the correct current component in the
appropriate configuration screen.

5. Download the changed SINAMICS project to the target system. The A01420
alarm disappears (it can be acknowledged). After the download, the serial
number of the new component is stored in the SINAMICS main memory.

6. Use "Copy RAM to ROM" via CU: p0971 = 1 or CU: p0977 = 1 to transfer
the values from the main memory of the SINAMICS to the CF card.
The module replacement has then been completed.

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Training Document 7 - 22 Topology
 For firmware SINAMICS 2.5 and higher, the system automatically upgrades/
downgrades the DRIVE-CLiQ components upon startup to the status of the
firmware version that is present on the CF card.
Components which cannot be downgraded to the components' firmware version
on the CF card (e.g. old firmware on the card and new components to which the
old firmware cannot be loaded) retain their firmware status. The resulting
firmware version combinations are system-tested and released.
An upgrade/downgrade operation in progress is indicated on the components by
a 0.5 Hz red-green flashing LED and on SINAMICS CU320-2 by a 0.5 Hz
yellow-flashing Ready LED.
A successfully completed firmware upgrade/downgrade is indicated on the
components by flashing at a frequency of 2 Hz and on the SINAMICS CU320-2
by yellow/green flashing at 2 Hz. After the upgrade/downgrade is completed, the
power must be cycled off and back on (POWER OFF/ON). The automatic
upgrade/downgrade function can be deactivated via parameter p7826 in the
STARTER.

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Training Document 7 - 23 Topology
DQI / DQ (SMI) Geber mit DRIVE-CLiQ-Schnittstelle.
DQI: Bei der DQI-Schnittstelle ist der DRIVE-CLiQ-Anschluss direkt am Geber.
DQ (SMI): Bei der DQ-Schnittstelle wird der DRIVE-CLiQ-Anschluss über einen
separaten Stecker angeschlossen. Das Modul nennt sich SMI (Sensor Module
Integrated).

DRIVE-CLiQ-Geber ist ein Absolutwertgeber (Absolute Encoder) mit integrierter DRIVE-CLiQ-

Schnittstelle.

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Training Document 7 - 24 Topology
abbreviations the abbreviation starts with the letters for the encoder type. Followed by the
resolution.
encoder without DRIVE-CLiQ: steps per turn
encoder with DRIVE-CLiQ: number of bits and DQ

encoder without DRIVE-CLiQ-interface

Type resolution / interface
AM xxxxS/R resolution: xxxx signals per turn
AS
IC
IN
HTL

encoder with DRIVE-CLiQ-interface

AM xxDQ resolution: xx bit (2 to the power of xx)
IC
AS
IN
R

with
AM: Absolute encoder Multiturn
AS: Absolute encoder Singleturn
IC: Incremental encoder sin/cos with elctronic commutation C- und D- track
IN: Incremental encoder sin/cos without electronic commutation
HTL: Incremental encoder with HTL-Signal
R: Resolver

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Training Document 7 - 25 Topology
Hinweis Multiturngeber haben immer noch ein Gebergetriebe wie zuvor und machen
damit die Umdrehungsauswertung. Lediglich die Hallsensoren sind nun in
einem Chip und nicht mehr diskret aufgebaut.

Absolutwertgeber Encoder AS20DQI : Absolutwertgeber 20 Bit Singleturn

(Auflösung 1048576, Geberintern 512 S/R)

Encoder AM20DQI : Absolutwertgeber 20 Bit Singleturn

(Auflösung 1048576, Geberintern 512 S/R)
+ 12 Bit Multiturn mit 4096 Umdrehungen.

Encoder AS24DQI : Absolutwertgeber 24 Bit Singleturn

(Auflösung 16777220, Geberintern 2048 S/R)

Encoder AM24DQI : Absolutwertgeber 24 Bit Singleturn

(Auflösung 16777220, Geberintern 2048 S/R)
+ 12 Bit Multiturn mit 4096 Umdrehungen.

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Training Document 7 - 26 Topology
 Using an empty (non-programmed) encoder module as replacement part
For SINAMICS SW 4.3 and higher, it is possible to use an empty, non-
programmed encoder module as a spare part. This allows spare parts held
locally to be used as a quick way to restore motor operation.
After mechanical replacement using an identical encoder type, the drive is
operational again.
We recommended that the drive is not permanently left without a programmed
encoder module, but that the encoder module is programmed at a later time. In
the meantime, after the drive has powered up, alarm "1840 - component found
without motor data" is output.

NOTE Sensor Modules, encoders and KTY are electrostatically sensitive devices!
Neither hands nor tools that could be electrostatically charged should come into
contact with the connections.
Only identical encoder types may be used.
Conversion to a different encoder type may only be carried out in the motor
factory or in a SIEMENS Service Center. In this case, the rating plate, and
possibly other components of the motor, must be replaced.

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Training Document 7 - 27 Topology
Prerequisites For writing the electronic rating plate
• SINAMICS firmware version, from V2.5 or higher
• Commissioning has been completed (all component numbers are less
than 200)
• There is an empty encoder module of the same type available.

Loading the electronic type plate into the encoder module:

The data are loaded after mechanical replacement and the system then started
up by setting the parameters.
• Parameter p4690 is used to define for which component number the data of
the electronic type plate should be backed up. This component number is
written to p4690.
• Parameter p4691 is set to "2" to start the write operation. The data saved at
the transfer point "/USER/SINAMICS/DATA/SMI_DATA/" are written to the
module.
• If the operation was successful, the parameter changes back to "0".
• After the system has been restarted, the drive involved is again ready for
operation.

Backing up electronic rating plates for all motors:

• Data backup is started by setting CU parameter p4692 to "1".
• After the data have been successfully backed up, parameter p4692
automatically returns to "10" -> "All data successful".
• The data are saved on the system CF card under the defined storage path
"/USER/SINAMICS/DATA/SMI_DATA/".

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Training Document 7 - 28 Topology
Safety information Please note that:
• The course instructions have been produced for:
 A course held by a course leader
 Activities carried out on special training equipment
• The training equipment is operated under laboratory conditions.
In case of doubt, always ask your course leader – particularly when handling
components that carry electrical current or which can move.
• When carrying out work on equipment, the safety information in the
associated product documentation must always be observed!
The training documents alone are not sufficient.

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Training Document 7 - 29 Topology
Task Change the connection of the DRIVE-CLiQ cable at the CU 320-2 DP and
analyze the displays at the unit itself and in STARTER:

1. Dearchive the "S120-Servo_1" and open it.

2. Download the data to the target device and test the project by traversing
both drives.
3. Switch off your training equipment.
4. At the CU 320-2 DP, change over the DRIVE-CLiQ cable from port "X101" to
port "X100".
5. Switch on the drive unit and go online. Note the messages.
CU320-2 DP / LED RDY (display/significance):

………………………………………………………………………………
BOP operating display / CU_S_004: r0002 (display/significance):

………………………………………………………………………………
STARTER alarms (display/significance):

………………………………………………………………………………

………………………………………………………………………………

Possible
countermeasures The following countermeasures are possible:
• Manual adaptation of the set topology to the actual wiring
• Automatic adaptation of the set topology to the actual wiring
• Correct the actual wiring

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Training Document 7 - 30 Topology
Task Manually adapt the set topology in the project to the actual wiring of the DRIVE-
CLiQ connections:

1. Open the topology

>> Topology
2. Compare the following
• Actual topology of the online view and the
• project set topology of the offline view
3. Using the mouse, in the project set topology, move the Double Motor Module
from port "X101" to port "X100" of the CU 320-2 DP.
4. Check whether this move can also be made in the set topology:

………………………………………………………………………………
5. Save the project to the hard disk.
6. Transfer the modified project set topology in the CU 320-2 DP using
"Download to target device" and backup the data in a non-volatile fashion
using "Copy RAM to ROM".
7. Response of the CU320-2 DP:

………………………………………………………………………………
8. Switch off your training equipment.
9. For the next exercise, change over the DRIVE-CLiQ cable of the CU 320-2
DP from port "X100" back to port "X101".

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Training Document 7 - 31 Topology
Task Now, automatically adapt the specified topology in the project to the actual
wiring of the DRIVE-CLiQ connections:

1. Open the topology

>> Topology
2. Compare the following
• Actual topology of the online view and the
• project set topology of the offline view
3. Start the routine "Acknowledge topology comparison" via the Expert list of
the CU_S_004: p9904 = 1
4. Response (after approx. 20 seconds):

………………………………………………………………………………
5. Start the process "Copy RAM to ROM".
6. Interpret the information of a "Set -- actual comparison":

………………………………………………………………………………
7. Start the process "Update topology".
8. Interpret the information of a "Project set -- actual comparison":

………………………………………………………………………………
9. Load the project to the PG/PC and start “Update topology“ again.
10. Interpret the information of a renewed
"Project set -- actual" comparison:

………………………………………………………………………………

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Training Document 7 - 32 Topology
Task Simulate the failure of a DRIVE-CLiQ node by interrupting the DRIVE-CLiQ
communication:

1. Switch on your training equipment.

2. Interrupt the DRIVE-CliQ connection for the Double Motor Module at port
"X203" to the SMC20 encoder interface.

3. Interpret the status messages of the LEDs regarding display and

significance:
CU320-2 DP / LED RDY:

………………………………………………………………………………
SMC20 / LED RDY:

………………………………………………………………………………
Double Motor Module / LED RDY:

………………………………………………………………………………

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Training Document 7 - 33 Topology
 4. Note down the fault and alarm messages and the associated descriptions
(as bullet points):
BOP 20:

………………………………………………………………………………
STARTER:

………………………………………………………………………………

………………………………………………………………………………

………………………………………………………………………………

………………………………………………………………………………

5. Reinsert the DRIVE-CLiQ connection into port "X203" of the Double Motor
Module.

6. Monitor the alarm messages.

7. Can the faults be acknowledged after re-establishing the DRIVE-CLiQ

connection (after approx. 30 seconds)?

………………………………………………………………………………

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Training Document 7 - 34 Topology
Task You can deactivate and activate DRIVE-CLiQ components in the graphic of the
set topology or in the expert list of the drive object (e.g. power unit: p125,
encoder interface: p145).

1. In the set topology, deactivate the DRIVE-CLiQ component "SERVO_03,

SMC20":
>> right mouse click > Status specification > Deactivate
2. To do this, remove the DRIVE-CLiQ connector from the Double Motor
Module port "X203".
3. How does the drive unit respond?: LED RDY on the CU 320-2 DP, Double
Motor Module, SMC 20:

………………………………………………………………………………
4. Which messages appear in STARTER and on the BOP 20:

………………………………………………………………………………
5. Switch the SERVO_03 to closed-loop control.
6. How does the drive unit respond?: LED RDY on the CU 320-2 DP, Double
Motor Module, SMC 20:

………………………………………………………………………………
7. Which messages appear in STARTER and on the BOP 20:

………………………………………………………………………………
8. Now restore the initial state by inserting the DRIVE-CLiQ cable into port
"X203" of the Double Motor Module and then activate "SERVO_03, SMC20"
in the offline mode.

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Training Document 7 - 35 Topology
Task Deactivate the drive SERVO_03:

1. Go to the object SERVO_03 in the expert list.

2. Deactivate the object using parameter p105:

p105 = ……………………………………..

3. What is shown on the operating display:

SERVO_03, r2 = ……………………………………..

4. Response after opening the DRIVE-CLiQ connection at port "X203":

………………………………………………………………………………

5. Response after switching-on SERVO_03:

………………………………………………………………………………

6. Now restore the initial state and test the drive.

Note Objects can only be deactivated and activated in the Expert list of the particular
object.

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Training Document 7 - 36 Topology
 If the CompactFlash card is removed when the device is switched on, the CU
generates the alarm “A1100 / CompactFlash card removed“; the device
continues to work properly.
However, if the CompactFlash card is reinserted during operation, no more data
can be saved. In this case, the alarm can only be acknowledged using a Power
ON reset.
Never withdraw the card during a write operation (flashing LED RDY) from the
CU320-2. If this is done, then the data structure on the card can be damaged,
which means that the card can no longer be used.

Task Investigate the behavior of the drive when removing and inserting the
CompactFlash card!

1. Start the drive servo_02.

2. With the drive operational, remove the flash card from the CU

Drive response: ……………………………………..

LEDs / BOP display: ……………………………………..

3. Reinsert the card.

Drive response: ……………………………………..

LEDs / BOP display: ……………………………………..

4. Choose: Copy RAM to ROM

Message: ……………………………………..

Note Generally, damaged files can be deleted using quick formatting (Type FAT 16).
The boot loader is retained after quick formatting. The image of the
CompactFlash card, previously saved via Explorer, can then be copied back to
the CompactFlash card.

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Training Document 7 - 37 Topology
Task Backup the parameterization on the CompactFlash card using a card reader
and Windows Explorer!

1. Connect the card reader to your PG/PC.

2. Open Windows Explorer and select the directory with the CompactFlash
card.

3. Copy the entire content of the card into any Windows folder, e.g. "Course".

4. Delete the entire content of the card for the next exercise.

5. Before you remove the CompactFlash card from the PG/PC,

use “Safely remove hardware“ (at bottom right of screen) to allow the
CompactFlash card to be removed.

Note With simple data deletion, the invisible “Boot Loader“ is not deleted. This means
that the card can still be used for SINAMICS S120.

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Training Document 7 - 38 Topology
Task Investigate how the drive powers up if there is no CompactFlash card or just an
empty one!

1. Switch on your drive unit without a CompactFlash card (if all LEDs light up
red, perform a Power ON reset again).

2. Note the states of the LEDs at the CU:

RDY: . . . . . . . . . . . . DP1: . . . . . . . . . . . . . OPT: . . . . . . . . . . . . .

3. Switch off the drive unit.

4. Insert the empty CompactFlash card.

5. Switch on your drive unit with deleted card.

6. Note the states of the LEDs at the CU:

RDY: . . . . . . . . . . . . DP1: . . . . . . . . . . . . . OPT: . . . . . . . . . . . . .

7. Note the states of the LEDs at the Motor Module:

RDY: . . . . . . . . . . . . DC: .............

8. Then ensure that an executable structure is written to your CompactFlash

card, and reinsert this back into your CU 320-2.

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Training Document 7 - 39 Topology
 Change the HW configuration of your training case with the power supply
switched off so that you can use the DQI motor from the maintenance case:

1. Changes on the motor module:

 Remove the DRIVE-CLiQ plug from port 2 (X202).
 Use the DRIVE-CLiQ cable supplied to connect the encoder of the DQI
motor to port 2 (X202) of the Motor Module.
 Use the supplied motor cable to connect the DQI motor to terminal X1 on
the Motor Module.

2. Switch the power supply to the training case on again.

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Training Document 7 - 40 Topology
Task After replacing the motor, the motor/encoder data must be read out from the
DRIVE-CLiQ rating plate and stored in the project.

1. Open the project and switch to offline mode and open the configuration
view of the "Filler_red" drive.
2. The next step is to start the "DDS configuration" (DDS: Drive Data Set) of
the drive.
3. Select "Read out motor again" in the motor data configuration.
4. Save the project.
5. Switch into online mode.
6. Which alarm message is present?

………………………………………………………………………………
7. Then perform a download, followed by "Copy RAM to ROM".
8. Load the output motor/encoder data back to the programming device
("Load project to PG" function).
9. The "Configuration" screen of the drive lists the components for this drive
object.
Note the order number of the motor, the SMI and the encoder type:

………………………………………………………………………………

………………………………………………………………………………

………………………………………………………………………………
10. Switch the SINAMICS power supply off and then on again.
11. Test the newly installed motor.

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Training Document 7 - 41 Topology
Task A DRIVE-CLiQ motor encoder has failed and is to be replaced.
To do this, the encoder will be replaced with a non-programmed encoder and
the saved motor data transferred to the new encoder.

Preparation Change the HW configuration of your training case with the power supply
switched off so that you can use the DQI motor from the maintenance case:

1. Changes on the motor module:

• Remove the DRIVE-CLiQ plug from port 2 (X202).
• Use the DRIVE-CLiQ cable supplied to connect the encoder of the DQI
motor to port 2 (X202) of the Motor Module.
• Use the supplied motor cable to connect the DQI motor to terminal X1 on
the Motor Module.

2. Open the project in additional exercise 4 or retrieve and open the training
project "IH_C071_S120_HMI_V46_GB". Your trainer will tell you the
directory.

3. Save the project, perform a download and then carry out "Copy "RAM to
ROM".

4. Switch off the SINAMICS supply voltage.

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Training Document 7 - 42 Topology
Task To meet the prerequisites for this exercise, delete any motor data present on
the CF card:

1. Switch off the SINAMICS S120 supply voltage.

2. Remove the CF card from the SINAMICS S120 and insert it into a card
reader.

3. Check the directory "/USER/SINAMICS/DATA/SMI_DATA/" on the CF card.

4. If the directory "SMI_DATA" exists, delete it.

5. Insert the CF card back into the SINAMICS S120.

6. Switch on the supply voltage of the SINAMICS S120.

7. Open the project and switch to online mode.

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Training Document 7 - 43 Topology
Task Backup the motor data of the DQI motor.
Then change the motor encoder mechanically
To back up the settings, proceed as follows:

1. Switch to the online mode of the STARTER project.

2. Open the Control Unit expert list.
3. Set parameter CU p4692 = 1 and you will receive the feedback in parameter
p4692. The parameter is then automatically set to 10: "All data saved
successfully".
4. Switch off the drive unit, remove the CF card and use the card reader to
check whether the back up of the motor data to
"/USER/SINAMICS/DATA/SMI_DATA/" has been successful.
5. Switch to the topology view in the offline STARTER project. Now determine
the component number of the DRIVE-CLiQ encoder (see example = 7).
Which component number have you determined?

………………………………………………………………………………

6. Switch off the supply voltage to SINAMICS.

7. Replace the DQI motor encoder.
• To do this, loosen the 4 fixing screws
• Remove the encoder
• CAUTION:
Sensor Modules, encoders and KTY are electrostatically sensitive
devices! Neither hands nor tools that could be electrostatically charged
should come into contact with the connections!
• Install the new encoder.

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Training Document 7 - 44 Topology
Task To meet the prerequisites for this exercise, delete any motor data present on
the DQI encoder module.
1. Insert the encoder connecting cable of the DQI motor to a non-assigned
DRIVE-CLiQ port.

2. Switch on the SINAMICS supply voltage.

3. Switch into online mode in the STARTER project.

4. Open the topology view of the drive unit.

5. Read out the component number of the DQI encoder module in the topology
(see example = 204).
Which component number have you determined?

………………………………………………………………………………

6. Now open the CU expert list and set the parameters in the following order:
• p4690 -> Entry of the component number determined above
(in the example = 204).
• p4691 -> Action: 30 -> "Delete SMI data".
• p4691 -> Message: 35 -> "Delete SMI data, confirmation
required".
• p4691 -> Action: 30 -> "Delete SMI data"
• p4691 -> Message: 36 -> "SMI data deleted, Power On
required for comp.“

7. Switch off the supply voltage to SINAMICS.

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Training Document 7 - 45 Topology
SITRAIN Page Course DR-S12-PM
Training Document 7 - ‹Nr.› Topology
Task The motor data stored on the CF card must be transferred to the DQI encoder:

1. Reconnect the DRIVE-CLiQ cable to its original port.

2. Switch on the SINAMICS supply voltage.

3. Which warning is displayed?

……………………………………………………………………………..

4. Open the CU expert list and set the parameters in the following order:
• p4690 -> Entry of the original component number
(in the example = 7)
• p4691 -> Action: 2 -> "Load SMI data"
• p4691 -> Message: 9 -> "SMI data loaded, Power On required for comp.“

5. Switch the SINAMICS supply voltage on and off.

6. Test the motor function.

Note The Projekte_de\CF-Card contains a copy of the CF card with valid encoder
data. Your trainer will tell you the directory.

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Training Document 7 - 46 Topology
Learning Targets .............................................................................................................................. 2
Overview .......................................................................................................................................... 3
Frame sizes ..................................................................................................................................... 4
Structure power unit ......................................................................................................................... 5
Communication modules .................................................................................................................. 6
Line Module ..................................................................................................................................... 7
Motor Module ................................................................................................................................... 12
Power Module .................................................................................................................................. 13
SINAMICS S150 ............................................................................................................................. 16
Power unit cooling ............................................................................................................................ 17
Option DC coupling .......................................................................................................................... 18
Braking Module ................................................................................................................................ 19
Line and motor-side components ..................................................................................................... 20
Cable lengths ................................................................................................................................... 21
Voltage sensing ............................................................................................................................... 22

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Training Document 8-1 Chassis and Cabinet power units
SITRAIN Page Course DR-S12-PM
Training Document 8-2 Chassis and Cabinet power units
SITRAIN Page Course DR-S12-PM
Training Document 8-3 Chassis and Cabinet power units
Frame sizes SINAMICS power blocks as built-in units or cabinet units are offered in the
following sizes:
• Frame size F (FS F): 1 short power block

• Frame size G (FS G): 1 long power block

• Frame size H (FS H): 2 long power blocks

(phase 1 on power block 1, phases 2 and 3 on power block 2)

• Frame size J (FS J): 3 long power blocks

(phase 1 on power block 1, phase 2 on power block 2, phase 3 on power
block 3)

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Training Document 8-4 Chassis and Cabinet power units
SITRAIN Page Course DR-S12-PM
Training Document 8-5 Chassis and Cabinet power units
SITRAIN Page Course DR-S12-PM
Training Document 8-6 Chassis and Cabinet power units
Basic Line Basic Line Modules are used for applications in which no energy is returned to
the supply or where the energy exchange between motor and generator axes
takes place in the DC link.
The connected Motor Modules are pre-charged via the thyristor gate control.
The thyristors are always fired at a delay angle of 0° in operation.
Basic Line Modules are designed for connection to grounded TN/TT systems
and non-grounded IT systems. In a Basic Line Module in chassis format, a
Braking Module of the corresponding size can be installed to support generating
mode of the drive system in combination with an external braking resistor.

Design The Basic Line Modules in chassis format feature the following connections and
interfaces as standard:
• 1 power connection
• 1 connection for the 24 V DC electronics power supply
• 1 DC link connection (DCP, DCN) for supplying the connected Motor
Modules
• 1 DC link connection (DCPA, DCNA) for connecting a Braking Module
• 1 temperature sensor input (KTY84-130 or PTC/Pt100)
• 3 DRIVE-CLiQ sockets
The status of the Basic Line Modules is indicated via two multi-color LEDs.

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Training Document 8-7 Chassis and Cabinet power units
Smart Line Smart Line Modules are non-regulated feed/feedback units with 100 %
continuous regenerative feedback power. The regenerative feedback capability
of the modules can be deactivated by means of parameterization.
Smart Line Modules are designed for connection to grounded TN/TT and non-
grounded IT systems.
The DC link is pre-charged via integrated pre-charging resistors.
The associated line reactor is absolutely essential for operating a Smart Line
Module.

Design The Smart Line Modules have the following interfaces as standard:
• 1 power connection
• 1 connection for the 24 V DC electronics power supply
• 1 DC link connection (DCPA, DCNA) for connecting a Braking Module
• 3 DRIVE-CLiQ sockets
• 1 PE (protective earth) connection (2 connections for frame sizes HX and JX)
The status of the Smart Line Modules is indicated via two multi-color LEDs.

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Training Document 8-8 Chassis and Cabinet power units
Active line The self-commutated feed/feedback units (with IGBTs in infeed and
regenerative feedback directions) generate a regulated DC link voltage. This
means that the connected Motor Modules are decoupled from the line voltage.
Line voltage fluctuations within the permissible supply tolerances have no effect
on the motor voltage.
Active Line Modules can if necessary feed a prespecified fundamental reactive
current (capacitive or inductive) to the supply system so as to support simple
compensation tasks.
Active Line Modules are designed for connection to grounded TN/TT and non-
grounded IT systems.
In order to operate an Active Line Module, it is absolutely essential to use the
appropriate Active Interface Module.

Design The Active Line Modules in chassis format feature the following connections
and interfaces as standard:
• 1 power connection
• 1 connection for the 24 V DC electronics power supply
• 1 DC link connection (DCP, DCN) for supplying the connected Motor
Modules
• 1 DC link connection (DCPA, DCNA) for connecting a Braking Module
• 1 temperature sensor input (KTY84-130 or PTC/Pt100)
• 3 DRIVE-CLiQ sockets
• 2 PE (protective earth) connections
The status of the Active Line Modules is indicated via two multi-color LEDs.

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Training Document 8-9 Chassis and Cabinet power units
Active Interface Active Interface Modules are used in combination with Active Line Modules in
chassis format. Active Interface Modules contain a Clean Power Filter with
basic RI suppression reactor, the pre-charging circuit for the Active Line
Module, the line voltage sensing circuit and monitoring sensors. The bypass
connector is an integral component in types FI and GI, thereby making the
module very compact. The bypass contactor must be provided separately for
frame sizes HI and JI.
The vast majority of line harmonics are suppressed by the Clean Power Filter.

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Training Document 8 - 10 Chassis and Cabinet power units
Connection The Active Interface Module requires a 24 V DC supply for operation of the
integral fan. The fan rotates after the 24 V DC supply is applied and can, if
necessary (service life, noise), be shut off fom the Control Unit over the "Fan
off" input. It is only permitted to switch off the fan when the infeed of the drive
system is not operating, otherwise the Active Interface Module will overheat.
The thermostatic switch installed in the Active Interface Module is evaluated
over the connected Active Line Module.
The power cables between the Active Interface Module and Active Line Module
must be shielded if limit values for interference suppression are to be complied
with. The cable shield can be routed over the shield connection plate (option) to
the Active Interface Module or Active Line Module.
Depending on the position of the Active Interface Module in the drive system,
additional DRIVE-CLiQ cables may be required. If it is separately installed next
to the left side of the Control Unit and Active Line Module, no additional DRIVE-
CLiQ cables are required.
If the Active Interface Module is placed between the Control Unit and Active
Line Module, the DRIVE-CLiQ cables supplied with the Active Line Modules are
suitable for setting up a line topology, i.e. Active Line Module and all Motor
Modules in series on one DRIVE-CLiQ line.

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Training Document 8 - 11 Chassis and Cabinet power units
Motor Module The Single Motor Modules in chassis format feature the following connections
and interfaces as standard:
• 1 DC link connection (DCP, DCN) for connecting to the supply DC busbar
• 1 DC link connection (DCPA, DCNA) for connecting a Braking Module
• 1 electronics power supply connection
• 3 DRIVE-CLiQ sockets
• 1 motor connection
• 1 safe standstill input (enable pulses)
• 1 temperature sensor input (KTY84-130 or Pt100 two-wire, or PTC)
• 1 connection for Safe Brake Adapter
• 1 PE (protective earth) connection
The status of the Motor Modules is indicated via two multi-color LEDs.

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Training Document 8 - 12 Chassis and Cabinet power units
Power Module The PM340 Power Modules in blocksize format feature the following
connections and interfaces as standard:
• Line connection
• PM-IF interface for connection of the PM340 Power Module and CU310-
2/SIMOTION D410-2 Control Unit or CUA31/CUA32 Control Unit Adapter.
The PM340 Power Module also supplies power to the CU310-2/SIMOTION
D410-2 Control Unit or CUA31/CUA32 Control Unit Adapter by means of an
integrated power supply
• Terminals DCP/R1 and R2 for connection of an external braking resistor
• Motor connection made with screw-type terminals or screw studs
• Control circuit for the Safe Brake Relay for controlling a holding brake
• 2 PE (protective earth) connections
Power Modules without integrated line filter can be connected to grounded
TN/TT and non-grounded IT systems.
Power Modules with integrated line filter are suitable only for connection to TN
systems with grounded star point.
The integrated Braking Unit (Braking Chopper) is rated with the capability to
continuously utilize the external braking resistor.
The temperature of the external braking resistor must be monitored to provide
protection against thermal overloading.

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Training Document 8 - 13 Chassis and Cabinet power units
Power Module The Power Modules in chassis format feature the following connections and
interfaces as standard:
• 1 power connection
• 2 DC link connections for options, e.g. Braking Modules
• 3 DRIVE-CLiQ sockets
• 1 safe standstill input (enable pulses)
• 1 temperature sensor input (KTY84-130 or PTC/Pt100)
• 1 electronics power supply connection
• 1 motor connection
• 1 connection for Safe Brake Adapter
• 2 PE (protective earth) connections
The CU310-2/SIMOTION D410-2 Control Unit can be mounted in Power
Modules of chassis format.

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Training Document 8 - 14 Chassis and Cabinet power units
Abkürzungen TDB: Thyristor Drive Board
IPD: Indiviual Power Data
CIM: Control Interface Module
LWL: Lichtwellenleiter
IGD: IGBT Drive Board

Control Unit Als Control Unit kann sowohl die CU310-2 (nur Einzelantrieb) als auch die
CU320-2 eingesetzt werden.

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Training Document 8 - 15 Chassis and Cabinet power units
SITRAIN Page Course DR-S12-PM
Training Document 8 - 16 Chassis and Cabinet power units
Water cooling For very high power and in some cases with extremely compact designs, liquid-
cooled converters are often preferred.
Particularly at higher ambient temperatures. the cooling capacity of the air flow
is not sufficient and a liquid-cooled converter is used in these case.
Installation altitudes higher than 2000 m above sea level, air-cooled converters
require derating (refer to catalog for details) – i.e. an appropriate power
reduction, which is why liquid-cooled converters are expedient here.

General conditions Liquid-cooled converters always require a heat exchanger (cooler) to

accommodate the heat of the power semiconductors in the primary circuit and
forward it to a secondary circuit.
The liquid in the primary circuit must satisfy special requirements for
conductivity (refer to the Commissioning Manual for details).

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Training Document 8 - 17 Chassis and Cabinet power units
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Training Document 8 - 18 Chassis and Cabinet power units
 Braking Modules and braking resistors fulfill the following function:
• Conversion of DC link energy to heat loss in the external braking resistor
• Because the Smart and Active Line Modules are feedback-capable, Braking
Modules and braking resistors are not required for normal operation.
These components must only be provided if a machine must specifically be
stopped at power failure (regenerative feedback no longer possible).
Installation
• The Chassis Braking Module is built directly in to a power block of a Motor
Module and does not require additional space in the control cabinet.
• The external braking resistor is installed outside of the control cabinet to
prevent unnecessary heating of the converter cabinet.

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Training Document 8 - 19 Chassis and Cabinet power units
dv/dt filter The voltage gradients are reduced to dV/dt < 500 V/us
• This limits the voltage peaks to < 1000 V with Voltage Peak Limiter (VPL)
• No special insulation required in the motor with 500/690 V converters
• No insulated motor bearings required
• Edge modulation is possible (higher output voltage)

Sine-wave filter Voltage gradients dV/dt are reduced to << 50 V/µs

• This reduces the voltage peaks to 1.1*√2*Vline
• No insulated motor bearings required
• Unshielded cables are possible (from EMC viewpoint)
• Minimization of noise, fewer losses in the motor
• Edge modulation is not possible
• Current derating must be considered
• Sine-wave filters are only available for max. 250 kW (380 – 480 V) or
for max. 132 kW (500 – 600 V)
• Pulse frequency must be limited to 4 kHz (400 V, < 250 kW)
or 2.5 kHz
• Output frequency must be limited to 150 Hz

Motor filter Reduction of the rate of increase of voltage dv/dt

from approx. 3–6 kV/us to approx. 500 V/us
• This reduces the current spikes, but
• the voltage spikes are not reduced

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Training Document 8 - 20 Chassis and Cabinet power units
Application area The DRIVE-CLiQ cables MOTION-CONNECT 500 are suitable for wiring up
DRIVE-CLiQ components (the connectors have IP 20 degree of protection at
both ends).
The DRIVE-CLiQ cables MOTION-CONNECT 800 have additional 24 V DC
cores. Therefore they are suitable for connecting Sensor Module Integrated
motors.
On the motor side the cables have a DRIVE-CLiQ connector in degree of
protection IP 67.

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Training Document 8 - 21 Chassis and Cabinet power units
Function The VSM10 can detect the exact line voltage characteristic and supports fault-
free operation of Line Modules when power supply conditions are unfavorable,
e.g. with severe voltage fluctuations or short-time interruptions. The phase
differential voltage can be measured, either grounded or isolated.
The VSM10 is integrated in chassis format Active Interface Modules and in the
chassis format Smart Line Modules. It can be used optionally with all booksize
format Active Line Modules and 16 kW or 36 kW Smart Line Modules.

Design The VSM10 has the following connections and interfaces:

• 1 connection for direct line voltage detection up to 690 V
• 1 connection for line voltage detection using voltage transformers, maximum
voltage 100 V
• 2 analog inputs (reserved for resonance monitoring in Active Interface
Modules in chassis format)
• 1 temperature sensor input (KTY84-130 or PTC) for thermal monitoring of
the line reactors
• 1 DRIVE-CLiQ socket
• 1 connection for the electronics power supply via the 24V DC supply
connector
• 1 plug-in jumper for either grounded (delivery state) or isolated
measurement
• 1 PE (protective earth) connection
The status of the VSM10 is indicated by a two-color LED.

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Training Document 8 - 22 Chassis and Cabinet power units
Learning Targets .............................................................................................................................. 2
Applications ..................................................................................................................................... 3
Requirements of the drive ................................................................................................................ 4
How does a drive system become dynamic? .................................................................................... 5
Different operating modes ................................................................................................................ 7
Closed-loop control structure ........................................................................................................... 9
Closed-loop control structure ............................................................................................................ 10
Controller optimization ...................................................................................................................... 19
Current controller ............................................................................................................................. 23
Speed controller ............................................................................................................................... 26
Technology controller ....................................................................................................................... 30
Position controller ............................................................................................................................. 32
Precontrol ........................................................................................................................................ 33
Exercise 1: Current controller optimization ....................................................................................... 36
Exercise 2: Stationary measurement ................................................................................................ 38
Exercise 3: Speed controller optimization ......................................................................................... 40
Exercise 4: Optimization in Servo mode ........................................................................................... 43
Exercise 5 – optional: Frequency response analysis ......................................................................... 45

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Training Document 9-1 Closed loop control structure servo mode
SITRAIN Page Course DR-S12-PM
Training Document 9-2 Closed loop control structure servo mode
Notes

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Training Document 9-3 Closed loop control structure servo mode
SITRAIN Page Course DR-S12-PM
Training Document 9-4 Closed loop control structure servo mode
SITRAIN Page Course DR-S12-PM
Training Document 9-5 Closed loop control structure servo mode
SITRAIN Page Course DR-S12-PM
Training Document 9-6 Closed loop control structure servo mode
SITRAIN Page Course DR-S12-PM
Training Document 9-7 Closed loop control structure servo mode
SITRAIN Page Course DR-S12-PM
Training Document 9-8 Closed loop control structure servo mode
 A cascade control comprising several integral control loops is used to control
the drives.
The control loops viewed from inside to out are as follows:
• Current/torque controller
• Speed controller
• Position controller/technology controller
Cascaded control loop structures have the advantage that they can be put into
operation stepwise from inside to out.
This closed-loop control structure is fixed and is adapted to the particular
application via the parameterization.

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Training Document 9-9 Closed loop control structure servo mode
Overview The closed-loop control structure is displayed in several screens in the
STARTER.
The signal characteristics in the control structure are displayed by moving from
one screen to the next.
The functions shown here are processed in the CU:
• Speed controller
• Torque setpoints
• Torque limitation
• Current setpoint filter
• Current controller
The function referred to here with "Power unit" is performed in the Motor
Module.

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Training Document 9 - 10 Closed loop control structure servo mode
Speed controller The speed controller controls the motor speed using the actual values from the
encoder (operation with encoder) or the calculated actual speed value from the
electric motor model (operation without encoder).

Speed setpoint Several sources are available for the speed setpoint:
• Fixed setpoint (when setpoint channel is enabled)
• Motorized potentiometer (when setpoint channel is enabled)
• Analog input of the TB30 or TM31
• Via PROFIDRIVE (via PROFIBUS or PROFINET telegram)
• Position controller output

Actual speed value The actual speed value is output from the motor encoder or it is calculated in
encoderless mode from the electric motor model.

Adaptation Speed-dependent adaptation of control parameters gain factor Kp and the

integral time Tn is possible.

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Training Document 9 - 11 Closed loop control structure servo mode
Torque setpoints The source of the respective torque setpoint mainly depends on the closed-loop
control function selected. In speed-controlled mode, the speed controller
calculates a torque that it supplies to the function "Torque setpoints".
In torque-controlled mode, the torque setpoint is wired directly to a
supplementary torque 1, 2 or 3. In position-controlled mode, in some cases, a
torque offset is generated by a torque pre-control which is also wired to a
supplementary torque 1, 2 or 3.

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Training Document 9 - 12 Closed loop control structure servo mode
Limits The torque setpoint can be limited by the following characteristics:
• Upper torque limit
• Lower torque limit
• Current limit
• Power limit

Protection The torque limits and current limits serve to protect the mechanical equipment,
the motor and the power units.

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Training Document 9 - 13 Closed loop control structure servo mode
Torque limit (upper) The "Upper torque limit" must be specified as a positive value in Nm, otherwise
the motor will be accelerated up to its maximum speed.

Torque limit (lower) The "Lower torque limit" must be specified as a negative value in Nm, otherwise
the motor will be accelerated up to its maximum speed in the negative direction.

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Training Document 9 - 14 Closed loop control structure servo mode
Current limit Depending on the operating mode, the effective current limit is formed as a
function of the following characteristics:
• Current limit
• Maximum motor current
• Maximum possible current of the power unit (Motor Module)

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Training Document 9 - 15 Closed loop control structure servo mode
Power limits A separate power limit can be specified in kW for motor mode and generator
mode.

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Training Document 9 - 16 Closed loop control structure servo mode
Current controller The current controller is designed as a closed-loop PI controller that controls a
torque generating current setpoint and a field-generating current setpoint.

Current setpoint The torque generating current setpoint is determined from the torque setpoint.
The field generating current setpoint is determined by SINAMICS itself.

Actual current value The actual current value is determined by the current transformers on the Motor
Module and, within the context of the motor model, resolved into a torque
generating current setpoint Iq and a field generating current setpoint Id. The
actual current values are available to the CU via the DRIVE-CLiQ connection
and therefore also to the current controller.

Adaptation The P gain of the current controller can be reduced (depending on the current)
by means of current controller adaptation. Current controller adaptation can be
deactivated with the setting p1402.2 = 0.

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Training Document 9 - 17 Closed loop control structure servo mode
Power unit Information for the power unit is displayed here. The current or voltage flow
within the power unit is displayed graphically. You can enter the power unit
operating values and show the rms phase currents under PWM (Pulse Width
Modulation) .

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Training Document 9 - 18 Closed loop control structure servo mode
Optimization In a control loop, it is necessary to adapt the controller to the controlled system
in order for the controller to satisfy the requirements.
As a cascade control, the closed-loop control is made up of the following
controllers:
• Current/torque controller
• Speed controller
• Position controller
The manipulated variable of the higher-level control loop is the command
variable for the lower-level control loop in this context.
Cascaded control structures are put into operation from inside to out. The
higher-level control loop is not closed and set until the lower-level control loop is
working properly.
Advantages of
cascade control Step-by-step commissioning of the control loops from inside to out
(Current  Speed  Position); independent settings. Lower-level controllers
form an equivalent time delay for the higher-level system and therefore
influence the command variable dynamics of the entire system.
This disadvantage can be compensated by precontrol of the lower-level control
loop. Simple limitation of the inner controlled variables by limiting the command
variables of the outer controller.The effects of nonlinearities are limited. The
higher-level controller has a controlled system with less nonlinearity.
Reduced delay times through compensation in the lower-level control
loop.Disturbance values are immediately responded to and more quickly
compensated in the lower-level controller.

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Training Document 9 - 19 Closed loop control structure servo mode
Core objectives Controller optimization is based primarily on the requirements of the respective
application. Whereas for drilling and milling, demanding requirements are
placed on surface quality, for bottling, packing and conveying, a highly dynamic
response and high speed are required.
Disturbance variables arising in the process must be responded to in the same
manner.
This means that a common optimization strategy cannot produce the desired
result.
The core objectives are therefore:
• Dynamic response
• Stability
• Accuracy
• Ruggedness

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Training Document 9 - 20 Closed loop control structure servo mode
Transfer behavior The transfer behavior describes the dependence of an output signal on an input
signal.
This transfer behavior can be described as a function:
as a quotient of a function of the output signal and of the input signal.
The transfer behavior can be analyzed by means of:
• Step response:
Many applications have a simple system (rigid system, two mass
oscillators), where this analysis is sufficient
• Frequency response analysis:
Required for complex systems (e.g. multi-mass oscillators)

Transfer function The transfer function is unknown in most cases.

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Training Document 9 - 21 Closed loop control structure servo mode
Step response The controller optimization in the time domain can be carried out via an analysis
of the step response. In this context, a setpoint step is applied to the controller
input and the actual value traced.
The controller is modified by changing control parameters so that the actual
value reaches the setpoint as desired.

Optimization When optimizing a PI controller via a step response, several steps are required.
The P component should always be optimized first.
On starting optimization, the I component must therefore be set extremely low to
enable the required effect of the P component to be identified:
 Set Tn to a large value
The controlled response must then be observed with step-by-step increases in
Kp. As soon as the actual value begins to oscillate slightly, Kp must be reduced
by approximately 50% to allow sufficient scope for optimizing the I component.
As soon as Kp has been set optimally, to optimize the I component, Tn is
reduced step-by-step until a small oscillation occurs again in the actual value.
Then it is recommended that Tn is increased to double the value to give the
control loop sufficient stability despite the highly dynamic response.

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Training Document 9 - 22 Closed loop control structure servo mode
Current controller The current controller is responsible for ensuring that the required current flows
through the motor despite all lags.

Controlled system Put simply, the controlled system comprises two lag elements.
1. Converter lag:
• Switching delays
• Delays in current measurement
• Sampling times

2. Motor delays
• Delay time due to motor inductance

Note The delay time of the converter is small compared to the delay time in the
motor.

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Training Document 9 - 23 Closed loop control structure servo mode
Requirements The actual value should quickly follow the setpoint. The controller is optimized
to the control response. The typical optimization method here is the absolute
value optimum, where a small overshoot up to 4.3% is permissible. This method
represents an appropriate compromise between dynamics and stability.

Disturbances The compensation of disturbances is not relevant in the current controller.

Possible disturbances in current control loop: Fluctuations in the DC link
voltage. Since these disturbances are slower than the current controller cycle,
they can be neglected here.

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Training Document 9 - 24 Closed loop control structure servo mode
SIEMENS motor With SIEMENS motors that have a DRIVE-CLiQ connection or can be selected
from the list of SIEMENS motors in the STARTER, the rated motor data and the
equivalent circuit diagrams are already available. The current controller is pre-
optimized at the factory in this case.

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Training Document 9 - 25 Closed loop control structure servo mode
Speed controller The speed controller controls the required speed at the motor.

Controlled system Put simply, the controlled system comprises two lag elements.
• Current controller lag:
 The current controller is displayed simply as a first-order lag element with
a lag time that results from the lag times of the current control system
• Lag in the mechanical system
 is described by the mechanical time constant

Components I component: motor, mechanical system (poss. 2 I components)

Equivalent time constant for current controller (appox. 3 ms as PT1)
Equivalent time constant for speed sensing (calculated or measured) 100 ms

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Training Document 9 - 26 Closed loop control structure servo mode
Requirements The speed controller must react quickly to changes in the specified speed.
At the same time, it must compensate for disturbance variables fast.
Disturbance variables are, for example:
• Load changes
• Pumps
In this way, the speed controller is also set to match the disturbance
compensation:
Optimum command variables (superimposed position controller): BO
Optimum disturbance variables from process, load changes: SO
The reaction to the change in disturbance variable is analyzed.
Characteristic response to change in command variable for speed controller:
43% overshoot

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Training Document 9 - 27 Closed loop control structure servo mode
SITRAIN Page Course DR-S12-PM
Training Document 9 - 28 Closed loop control structure servo mode
 In the Automatic Controller Setting screen form, you can configure an automatic
setting of the speed controller for SINAMICS drive units. The necessary steps
for this calculation can be controlled from this screen. The calculated parameter
values of the speed controller are displayed and can then either be rejected or
adopted for the drive.

Features The automatic speed controller setting has the following features:
• Damping resonance effects in the speed-controlled system
• Automatic setting of the gain factor Kp and the integral time Tn of the speed
controller

Note The speed setpoint filter and the reference model are not adapted by the
automatic speed controller setting.

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Training Document 9 - 29 Closed loop control structure servo mode
Technology controller The technology controller can be used as a superimposed controller,
e.g.:
• Position controller
• Pressure controller
• Tension controller
• Fill level controller
• Flow controller

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Training Document 9 - 30 Closed loop control structure servo mode
Position control The position controller has the task of moving the drive to a specified target
position. The precondition for this is that the actual position is sensed by an
encoder. The measurement of the actual position is indicated as the integration
of the velocity in the signal flow.
The position controller is often set up as a P controller, since the system already
has an integration element.The gain factor of the position controller is called the
Kv factor.

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Training Document 9 - 31 Closed loop control structure servo mode
Optimization The position controller is designed so that the drive does not overshoot beyond
the specified end position.

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Training Document 9 - 32 Closed loop control structure servo mode
Precontrol The conventional position control concept (P controller) always requires a
deviation (following error = FE) between position setpoint and actual position
value. This deviation can lead to an unwanted axis behavior, such as contour
errors, poor dynamics (performance characteristics during rise time).
The task of the precontrol is to compensate these disadvantages. The
precontrol calculates the axis (setpoint) velocity directly from the position
setpoints by differentiation, multiplies it with the KPC factor, then transfers it
directly to the position controller output. In the best case, the precontrol setpoint
will cause the axis to move at the velocity calculated by the interpolator.
If the actual axis position were immediately returned to the position controller,
the following error would be 0. The position controller would then only have to
deal with the task of correcting disturbance-induced fluctuations of the real
actual axis position.

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Training Document 9 - 33 Closed loop control structure servo mode
Torque precontrol The innermost control loop can also be precontrolled by specifying the
acceleration or the torque on the current controller. The precontrol can also be
used to specify the motor torque setpoints.

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Training Document 9 - 34 Closed loop control structure servo mode
Safety information Please note that:
• The course instructions have been produced for:
 A course held by a course leader
 Activities carried out on special training equipment
• The training equipment is operated under laboratory conditions.
In case of doubt, always ask your course leader – particularly when handling
components that carry electrical current or which can move.
• When carrying out work on equipment, the safety information in the
associated product documentation must always be observed!
The training documents alone are not sufficient.

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Training Document 9 - 35 Closed loop control structure servo mode
Task The settings for the current controller have been pre-assigned automatically by
the software on the basis of the motor order number selected.
The task here is to check the settings on the basis of the measuring function.

1. Dearchive the project "S120_Servo_1", load the data to the CU and test the
drives.

2. Select the measuring function via the "Commissioning" directory in the

"Servo_02" drive object.

3. The following parameters should be set:

• Measuring function: Current controller setpoint change
• The other parameters are set automatically but may be modified for
measurement.
• The recorded parameters are also selected automatically.

4. The measurement must be started via the setpoint change.

5. Select the "Assume control priority" button and start the measurement by
pressing the green button.

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Training Document 9 - 36 Closed loop control structure servo mode
Result The result of the measurement is shown in the time diagram. Measure the rise
and recovery time.

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Training Document 9 - 37 Closed loop control structure servo mode
Task For third-party motors, the electrical parameters can be determined by
stationary measurement. This method of determining the motor parameters
must be carried out prior to current controller optimization.
If Siemens motors are used, current controller optimization can be carried out
without measurement of the motor parameters.

1. Select the stationary measurement in the following way:

>> Servo_02 > Commissioning > Stationary/turning measurement
and then perform the following steps:

2. Select the measuring mode: >> stationary measurement

3. Activate the measurement by pressing the button

"Activate measurement". The control panel is automatically opened for this
drive.

4. In the opened control panel, press the button

"Assume control priority!“ and accept the safety note

5. Set the "Enables" check mark, and then press the "green" button to start the
measurement.

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Training Document 9 - 38 Closed loop control structure servo mode
Result The measurement has been performed and the measurement results with the
stored values are then shown in a table.

6. Accept the data determined in the stationary measurement:

>> Accept values

The values are accepted but not saved to ROM. To retain the values after
switch-on, the data must be saved to ROM and downloaded to the PG and
saved on the hard disk.

Note The current controller only operates with the new values after the determined
values have been accepted.
If the values are not accepted, then the current controller continues to operate
with the previous values.

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Training Document 9 - 39 Closed loop control structure servo mode
Task The settings for the speed controller have been pre-assigned automatically by
the software.
The task here is to check and optimize the settings on the basis of the
measuring function.

1. Select the measuring function via the "Commissioning" directory in the

"Servo_02" drive object.
The following parameters should be set:
Measuring function: "Speed controller setpoint jump (after speed setpoint
filter)"
The other parameters are set automatically but may be modified for
measurement.
The recorded parameters are also selected automatically.

2. The measurement must be started via the setpoint change.

Select the "Assume control priority" button and start the measurement by
pressing the green button.

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Training Document 9 - 40 Closed loop control structure servo mode
Basic procedure The PI controller consists of a proportional (P) component and an integral (I)
component. The question therefore arises as to which component should be
optimized first.
The P component has an immediate effect on the setpoint/actual value
comparison, but the I component has a delayed effect due to its time constant,
so you must always begin by optimizing the P component.
On starting optimization, the I component must therefore be set extremely low to
enable the required effect of the P component to be identified:
 Set Tn to a large value.
Then apply the setpoint step change to the controller and observe the controlled
response. If the change in actual value is still extremely slow, increase Kp step-
by-step. If the actual value starts to oscillate, reduce Kp accordingly.
As soon as Kp has been set optimally, to optimize the I component, Tn is
reduced step-by-step until the first undershoot occurs in the actual value.
If necessary, with a further reduction in Tn, the height of the first overshoot
can be reduced.

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Training Document 9 - 41 Closed loop control structure servo mode
Task The speed controller parameter P gain and integral time must be adapted to the
mechanical conditions.
Before you carry out automatic optimization to determine this parameter, both
parameters should be changed manually and the result evaluated using a
setpoint step change.

1. Open the screen

>> Servo_02 > Open-loop/closed-loop control > Speed controller

2. Modify the parameters there

- P gain and
- Integral time

3. Then start the measurement.

Note If the STARTER is connected to the drive unit (online mode), the changes to the
P gain and integral time parameters are adopted immediately after input.
After optimization, the parameters must be saved to ROM and downloaded to
the PG and stored there.

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Training Document 9 - 42 Closed loop control structure servo mode
Task Besides manual setting of the speed controller parameters, it is also possible to
carry out automatic controller optimization.
Select the autonomous function provided in the following way:
>> Servo_02 > Commissioning > Automatic controller setting
and then perform the following steps:

1. Assume the control priority for your PC, and observe the safety instructions.

2. Switch-on the selected drive using the "green" button.

3. Press the button "Execute next step“.

4. In step 1, the mechanical system is measured at low frequencies.

5. In step 2, the mechanical system is measured at higher frequencies.

6. In step 3, the current controller is optimized.

7. In step 4, the speed controller is optimized.

8. Analyze, for example, the speed controller parameters "actual value" and
"calculated value".

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Training Document 9 - 43 Closed loop control structure servo mode
Task Accept the data determined in the automatic controller optimization:
>> Accept optimized settings in the drive? > Accept values

Note The current and speed controllers only operate with these new values after the
calculated values have been accepted. If the values are not accepted, then the
current and speed controllers continue to operate with the previous values.

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Training Document 9 - 44 Closed loop control structure servo mode
Additional task Besides analysis of the closed-loop control using the step response, the drive
also provides for frequency response analysis.
In this exercise, a frequency response analysis is to be initiated.

1. Select the measuring function via the "Commissioning" directory in the

"Servo_02" drive object.
The following parameters should be set:
• Measuring function:
Speed controller setpoint frequency response (after speed setpoint filter)
• The other parameters are set automatically but may be modified for
measurement.
• The recorded parameters are also selected automatically.

2. Select the "Assume control priority" button and start the measurement by
pressing the green button.

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Training Document 9 - 45 Closed loop control structure servo mode
Result The result of measurement for the frequency response analysis is shown in the
Bode diagram.

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Training Document 9 - 46 Closed loop control structure servo mode
Learning Targets .............................................................................................................................. 2
Induction motor ................................................................................................................................ 3
Closed-loop control structure ............................................................................................................ 7
Steps in the commissioning sequence .............................................................................................. 8
Steps in commissioning sequence .................................................................................................... 9
Steps in the commissioning sequence .............................................................................................. 10
Closed-loop and open-loop control modes ....................................................................................... 13
Open-loop control mode: U/f curve ................................................................................................... 14
Open-loop control mode: U/f characteristic ....................................................................................... 16
Exercise 1: Setting up training equipment with induction motor ......................................................... 18
Exercise 2: Commissioning an induction motor ................................................................................ 20
Exercise 3: Stationary measurement ................................................................................................ 23
Exercise 4: Turning measurement .................................................................................................... 25
Exercise 5: measuring functions ....................................................................................................... 26

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Training Document 10 - 1 Closed loop control structure servo mode
SITRAIN Page Course DR-S12-PM
Training Document 10 - 2 Closed loop control structure servo mode
Design The most important components of the induction motor are:
• Stator
• Rotor

Stator The stator consists of punched steel sheets, layered to produce the round outer
shape of the motor. There are slots on the inside to accommodate the windings.

Rotor The rotor is also made of punched sheets. These sheets produce continuous,
rod-like hollow cavities when placed one on top of the other. These cavities are
cast in aluminum and then form the current-carrying rods.
For a short-circuit rotor, the short-circuit rings are also cast in aluminum at both
ends. Ultimately, current flows through the aluminum; the sheet serves to
conduct the magnetic field lines and for mechanical installation.
In the case of high-efficiency motors, the aluminum is partially or wholly
replaced by copper.

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Training Document 10 - 3 Closed loop control structure servo mode
Lorentz force If electrons move in a magnetic field, they are subject to a force: the Lorentz
force.

Force generation This force also acts on a current-carrying conductor. If this conductor has a
vertical orientation to the magnetic lines of force, the Lorentz force will also act
vertically.
Right-hand rule:
• Thumb - Current direction
• Index finger - Direction of magnetic field
• Middle finger - Direction of force
The dynamic effect causes the motor to rotate.
Depending on the motor type, either the electrical conductors, the magnetic
field, or both will rotate:
• Synchronous servo motor: The rotor with magnets rotates.
• Induction motor: The magnetic field and conductors rotate, although at
different frequencies

Two components The following are, therefore, always required:

• Magnetic field
• Current-carrying conductor

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Training Document 10 - 4 Closed loop control structure servo mode
Induction machine In contrast to permanently excited synchronous machines, for induction
machines a field generating current must already be generated in the basic
speed range in order to enable any torque at all.
This means that for the closed-loop control of induction machines, non-zero field
and torque generating currents must always be specified and controlled.
The field generating current in the induction machine is the magnetization
current. The orientation of the rotor flux is calculated in the motor model. This
forms the orientation for the rotor coordinate system dq.
The accuracy of the motor model (e.g., influence of the temperature rise and
saturation) and that of the current and speed measurements determine the
quality of the field-oriented closed-loop control.

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Training Document 10 - 5 Closed loop control structure servo mode
Equivalent circuit The currents in the stator and rotor come up against both ohmic and inductive
resistances, where inductances at high frequencies are significant.
The magnetic field generated by the stator is linked to the rotor's magnetic field.
This is referred to as main field inductance and is represented as a single
component.
In part, these values are largely dependent on the frequency and temperature,
meaning that a precise mathematical simulation of the motor can be difficult to
achieve.
Parameters
in the converter Practically all modern converters work internally with parameters which contain
equivalent circuit diagrams. The values are preassigned automatically during
commissioning:
• Calculated from the rating plate data
• Via automatic converter measurements (motor identification), if required
The equivalent circuit diagram data are entered manually in special cases only.

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Training Document 10 - 6 Closed loop control structure servo mode
SITRAIN Page Course DR-S12-PM
Training Document 10 - 7 Closed loop control structure servo mode
SITRAIN Page Course DR-S12-PM
Training Document 10 - 8 Closed loop control structure servo mode
SITRAIN Page Course DR-S12-PM
Training Document 10 - 9 Closed loop control structure servo mode
SITRAIN Page Course DR-S12-PM
Training Document 10 - 10 Closed loop control structure servo mode
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Training Document 10 - 11 Closed loop control structure servo mode
SITRAIN Page Course DR-S12-PM
Training Document 10 - 12 Closed loop control structure servo mode
Speed control The speed controller controls the motor speed using the actual values from the
encoder (operation with encoder) or the calculated actual speed value from the
electric motor model (operation without encoder).

Torque control An operating mode switchover (p1300) can be carried out or a binector input
(p1501) used to switch from speed control to torque control mode. All torque
setpoints from the speed control system are rendered inactive. The setpoints for
torque control mode are selected by parameter assignment.

Linear characteristic Standard (w/o voltage boost)

Linear characteristic with

flux current control Characteristic that compensates for voltage losses in the stator resistance for
static/dynamic loads (flux current control FCC). This is particularly useful for
small motors, since they have a relatively high stator resistance.
Parabolic
characteristic Characteristic that takes into account the torque curve of the load
(e.g. fans/pumps)
a) Quadratic characteristic (f2 characteristic)
b) Energy-saving, because the low voltage results in smaller currents and
losses.
Programmable
characteristic Characteristic that takes into account the motor/machine torque curve
(e.g. synchronous motor)
Precise frequency
drives Characteristic that takes into account the technological particularity of an
application (e.g. textile applications).

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Training Document 10 - 13 Closed loop control structure servo mode
U/f control The simplest solution for a control procedure is the U/f characteristic, whereby
the stator voltage for the induction motor or synchronous motor is controlled
proportionately to the stator frequency. This method has proved successful in a
wide range of applications with low dynamic requirements, such as:
• Pumps and fans
• Belt drives
and other similar processes.

U/f characteristic U/f control aims to maintain a constant flux Φ in the motor Whereby this is pro-
portional to the magnetizing current Iµ or the ratio of voltage U to frequency f.
The torque M generated by the asynchronous motors is itself proportional to the
product (or more accurately, the vectorial product Φ x I) of flux and current.
To generate the highest possible torque at a given current, the motor must
operate at a constant, high level of flux. To maintain a constant flux (Φ),
therefore, the voltage (U) must be changed in proportion to the frequency (f) to
ensure a constant magnetization current (Iµ). U/f characteristic control is
derived from these basic premises.

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Training Document 10 - 14 Closed loop control structure servo mode
Voltage boost With an output frequency of 0 Hz, the U/f characteristics yield an output voltage
of 0 V. The voltage boost must be entered to:
• Magnetize the induction motor
• Maintain the load
• Compensate for the losses (ohmic losses in the winding resistors) in the
system or
• Generate a breakaway/acceleration/braking torque.
The voltage boost can be increased permanently (p1310) or during acceleration
(p1311).

Slip compensation Slip compensation is an additional U/f control function. It ensures that the actual
speed of induction motors is maintained at a constant level irrespective of the
load.

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Training Document 10 - 15 Closed loop control structure servo mode
Description With U/f control, the motor is operated with an open control loop and does not
require speed control or actual current sensing, for example. Operation is
possible with a small amount of motor data.
U/f control can be used to check the following:
• Motor Module
• Power cable between Motor Module and motor
• Motor
• DRIVE-CLiQ cable between Motor Module and motor
• Encoder and actual encoder value
The following motors can be operated with U/f control:
• Induction motors
• Synchronous motors

Caution U/f control must only be used as a diagnostic function with synchronous motors,
e.g. to check that the motor encoder is functioning correctly.

Note With operation with encoder, the actual speed value from the measuring system
is displayed
With operation without encoder, a calculated actual speed value is displayed.
The operation of synchronous motors with U/f control is permitted only at up to
25% of the rated motor speed.

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Training Document 10 - 16 Closed loop control structure servo mode
Safety information Please note that:
• The course instructions have been produced for:
 A course held by a course leader
 Activities carried out on special training equipment
• The training equipment is operated under laboratory conditions.
In case of doubt, always ask your course leader – particularly when handling
components that carry electrical current or which can move.
• When carrying out work on equipment, the safety information in the
associated product documentation must always be observed!
The training documents alone are not sufficient.

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Training Document 10 - 17 Closed loop control structure servo mode
Task Change the setup of your training case, so that for the operation of an induction
motor (ASM) you have a vector application with:
• 1LA7 induction motor
• HTL 1024 incremental encoder and
• Sensor Module Cabinet SMC30.

Procedure Perform the following steps as preparation:

1. Turn off the power supply of your training case.

2. Make the following changes at the Double Motor Module:

• Remove both DRIVE-CLiQ plugs from port X202 and X203.
• Insert the DRIVE-CLiQ plug of the SMC30 into port X202
• Disconnect the 1FK7 servo motor from the power connection X1
(open the screw coupling or withdraw the connector)
• Connect the 1LA7 induction motor with power connection X1
(screw coupling or connector)
• Connect the 24V supply for the SMC30 at the sockets of the training case
prepared for this purpose

3. In Starter, close your existing project, and create a new project for the
"Vector" operating mode.

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Training Document 10 - 18 Closed loop control structure servo mode
 4. Determine the code number of the HTL encoder. Check the assignment of
connectors X521 and X531 at the SMC30:
Are tracks A and B connected with twisted cables?

………………………………………………………………………………

Is the reference signal connected?

………………………………………………………………………………

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Training Document 10 - 19 Closed loop control structure servo mode
Task Carry out a first commissioning of your training equipment in the "Vector"
operating mode.

Procedure Work through the following steps:

1. Create a new project with the name "S120_Vector_1'.

2. Use the "Accessible nodes" button to search for the Control Unit in the
network.

3. Transfer the node to your project.

4. Establish an online connection to your training equipment.

5. Restore the factory settings.

6. Run through the automatic configuration:

>> Automatic configuration > Configuring

7. Create the "Vector" object.

8. Go offline to configure the vector drive.

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Training Document 10 - 20 Closed loop control structure servo mode
Task Configure the VECTOR_02 drive.

1. Delete the VECTOR_03 drive:

>> Right mouse click > Delete

2. Configure the VECTOR_02 drive:

>> Configuration > Configure DDS…

3. Make the following settings:

• Speed control with encoder
• Power unit unchanged
• Signal source for the signal "Infeed in operation":
>> Digital input DI16 of the CU320-2DP
• Motor at connection "X1" (connection X2 remains undefined)
• IEC motor, connection voltage 600 V
(value is changed later online)

4. Enter the motor data in the delta connection:

• 1LA7 standard induction motor [17]
• p304 = 230 V
• p305 = 0.73 A
• p307 = 0.12 kW
• p308 = 0.75
• p310 = 50 Hz
• p311 = 1350 rpm
• p355 = [0] non-ventilated

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Training Document 10 - 21 Closed loop control structure servo mode
 5. Then select:
• Without entering optional data
• Without entering the equivalent circuit diagram data
• Complete calculation with equivalent circuit diagram data
• No motor holding brake
6. Select the HTL encoder that you determined beforehand from the list of
standard encoders.
Note: After completing the configuration, or online, it is possible to change
the encoder type via the Expert list: p0010=1 > p400=code >p010=0
7. Then select:
• Standard drive VECTOR, motor identification: Disabled (0)
• Free telegram configuration with BICO
8. Enter important parameters, such as a ramp-up time and ramp-down time
according to the screenshot above.
9. Then select Finish.
10. Save the project
11. Go online with the drive unit, open the expert list of VECTOR_02 and set
the following parameters:
• p210: 380 V
• p278: -80 V
• p340: 1
12. Save the data to ROM, load the data to the PG and save the project on
your hard disk.

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Training Document 10 - 22 Closed loop control structure servo mode
 When configuring the drive, it is possible to pre-select stationary [2] or stationary
plus turning measurement [1]. These measurements are then activated when
the drive is switched on for the first time (and the second time) without further
parameterization.

Task In this exercise, performance of the stationary and turning measurement is

selected via:>> Commissioning > Stationary/turning measurement.

1. Select the Stationary measurement in the following way:

>> Vector_02 > Commissioning > Stationary/turning measurement
and then carry out the following steps:

2. Select the measuring mode: >> stationary measurement

3. To estimate the measurement result, note the following parameters prior to

measurement:
p350: Motor stator resistance
p356: Motor leakage inductance
Kp current controller
Tn current controller

4. Activate the measurement by pressing the button

"Activate measurement". The control panel for this drive opens
automatically.
Perform a function test for the new drive.

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Training Document 10 - 23 Closed loop control structure servo mode
Task Open the control panel.
Give up the control priority.

1. Compare the values before and after measurement.

2. Save the parameterization to the ROM of the drive, computer and on the
hard disk.

3. After motor identification, the drive can be turned by specifying a setpoint.

Enter a setpoint of 100 rpm and start the drive.

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Training Document 10 - 24 Closed loop control structure servo mode
Task You want to optimize your closed-loop cascade control, comprising current and
speed controllers with the stationary and turning measurement.

1. Select the turning measurement in the following way:

>> Vector_02 > Commissioning > Stationary/turning measurement

and then carry out the following steps:

2. Select the measuring mode: >> stationary measurement (with encoder)

3. Activate the measurement by pressing the button

"Activate measurement". The control panel is automatically opened for this
drive.

4. In the opened control panel, press the button

"Assume control priority!“ and accept the safety note

5. Set the "Enables" check mark, and then press the "green" button to start the
measurement.

6. Save the data in Rom and in the project on the harddisk.

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Training Document 10 - 25 Closed loop control structure servo mode
 It makes sense to check the parameters which are measured during stationary
and turning measurement. This can be done with the measuring functions.
Task
1. Select the measuring functions in the following way:
>> Vector_02 > Commissioning > measuring functions
and then carry out the following steps:

2. Select the measuring function: current controller setpoint jump (after filter).
The parameters for measuring and the signals for the trace are set. Both can
be changed.

3. Activate the measurement by pressing the button “Assume Control priority”

an start the measurement wit the green button.

4. The results are shown in the trace.

5. Select the measuring function: speed controller setpoint (after speed setpoint
filter). The parameters for measuring and the signals for the trace are set.
Both can be changed.

6. Activate the measurement by pressing the button “Assume Control priority”

an start the measurement wit the green button.

7. The results are shown in the trace.

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Training Document 10 - 26 Closed loop control structure servo mode
Learning Targets .............................................................................................................................. 2
Speed setpoint channel .................................................................................................................... 3
Speed setpoint sources .................................................................................................................... 4
Limits ............................................................................................................................................... 7
Ramp-function generator .................................................................................................................. 8
Setpoint addition .............................................................................................................................. 9
Exercise 1: Setpoint channel and BICO interconnection .................................................................... 11

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Training Document 11 - 1 Setpoint channel
SITRAIN Page Course DR-S12-PM
Training Document 11 - 2 Setpoint channel
Setpoint channel The speed setpoint channel is used to prepare a speed setpoint and therefore
includes the following functions:
• Main and supplementary setpoint or jog setpoint
• Direction of rotation reversal
• Direction of rotation inhibit
• Limit
• Skip frequencies
• Ramp-function generator

Setpoint sources The speed setpoint required for speed control can be provided from the
following sources within the setpoint channel:
• Fixed setpoint (from the table of fixed setpoints)
• Motor potentiometer (with manual/automatic switchover)
In addition, the following setpoint sources are available irrespective of the
setpoint channel:
• Analog input (e.g. from TB30 or TM31)
• PROFIDRIVE (via PROFIBUS or PROFINET)

Note In "Vector" mode, the speed setpoint channel is an elementary part of the
closed-loop control structure; while in "Servo" mode, the speed setpoint channel
must be enabled during configuration.

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Training Document 11 - 3 Setpoint channel
Fixed setpoints 16 different fixed setpoints are available for speed setpoint input, whereby fixed
setpoint 0 is preset with the value "0". This is also the factory preset for the main
setpoint (p1070).
The four control bits p1020 … p1023 can be used to select the 15 freely
selectable fixed setpoints p1001 … p1015 and "0".
The selected fixed setpoint r1024 can be connected, but also the individual
values p1001 … p1015.
The number of the fixed setpoint that is switched through is indicated via r1197.

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Training Document 11 - 4 Setpoint channel
 Using the buttons "Setpoint higher" and "Setpoint lower", a speed setpoint
between the "Maximum value" and "Minimum value" can be provided. The
gradient is defined by the ramp-function generator available here.

Note During offline configuration, value assignment is initially disabled for a series of
appropriately marked parameters, e.g. for parameter p1038 (see shaded field).
Typically, these values can be changed online immediately, but offline they can
only be changed after an upload, when the CU has finished calculating.
As soon as parameter p340 = 1 (full calculation) is set the two parameters
p1037 (maximum value) and p1038 (minimum value) are cross-hatched in gray
and cannot be changed. These two parameters can only be changed as
required when the calculation has finished.

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Training Document 11 - 5 Setpoint channel
Main setpoint The speed setpoint source is connected with this parameter (p1070).
Supplementary
setpoint Alongside the main setpoint, parameter p1075 makes an additional input
available via which, for example, a speed setpoint offset can be connected. In
various application cases, the supplementary setpoint is used as an alter-native
to the main setpoint and it is appropriately weighted by the two scaling
parameters p1071 and p1076 or even completely switched off (scaling: 0%).

Direction reversal When this is activated the direction can be reversed.

Negative direction
inhibit When this is activated, the setpoint for the motor is inhibited in the negative
direction (e.g. for pumps that may only be operated in the positive direction!).
Positive direction
inhibit When this is activated, the motor is inhibited in the positive direction.

Note If both directions of rotation are inhibited simultaneously, the motor can only
operate at speed "0".

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Training Document 11 - 6 Setpoint channel
Skip frequency bands These are used to suppress unfavorable speed ranges, such as resonant
speeds. A total of 4 skip frequency bands can be defined with the same
hysteresis band width.

Minimum limit Minimum speed at which this motor will operate following speed controller
enable.

Maximum limit This limits the speed in the positive and negative directions of rotation.
As the criterion for this, the max. motor speed (p1082), that is effective as a limit
in both directions, is entered as well as an individually adjustable limit for the
positive direction (p1083) and a limit for the negative direction (p1086).
The most limiting in the applicable direction is effective at the output for the
maximum limit.

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Training Document 11 - 7 Setpoint channel
 The basic ramp-function generator is defined by the following parameters:
• Ramp-up time (p1120)
• OFF1 ramp-down time (p1121)
• OFF3 ramp-down time (p1135)
These parameters reference the maximum speed for this motor (p1082).
Extended ramp-
function generator In contrast to the basic ramp-function generator, in the case of the extended
ramp-function generator, additional time constants are available for initial
rounding and final rounding. Additional rounding parameters are available for a
quick stop with OFF3.
Bypass ramp-
function generator The control bit "Bypass ramp-function generator" is used to switch off the ramp-
up and ramp-down functions as well as the rounding of the ramp-function
generator. It must, however, be checked beforehand whether this is permitted
for the connected mechanical system.

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Training Document 11 - 8 Setpoint channel
Setpoint addition Apart from the speed setpoint conditioned by the speed setpoint channel, two
additional speed setpoint offsets can be connected if required by means of
speed setpoint 1 (p1155) and speed setpoint 2 (p1160).

This possibility is frequently used with speed precontrols or static speed offsets.

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Training Document 11 - 9 Setpoint channel
Safety information Please note that:
• The course instructions have been produced for:
 A course held by a course leader
 Activities carried out on special training equipment
• The training equipment is operated under laboratory conditions.
In case of doubt, always ask your course leader – particularly when handling
components that carry electrical current or which can move.
• When carrying out work on equipment, the safety information in the
associated product documentation must always be observed!
The training documents alone are not sufficient.

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Training Document 11 - 10 Setpoint channel
Description You can use this exercise to train your skills in interconnecting signals using
BiCo technology.
In the task, fixed setpoints, motorized potentiometer, analog setpoints as well as
control and status bits are interconnected with one another in a complex
fashion.

Note You can use the overview above, or follow the detailed task description on the
next slides.

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Training Document 11 - 11 Setpoint channel
Operating mode Perform this exercise, depending on the requirement in the "Servo" or "Vector"
operating mode. When required, dearchive the appropriate project in the
automatically recommended directory:
Project > Dearchive: Select project > Open
• "Servo" operating object: Project "S120_SERVO_V46.zip"
• "Vector" operating object: Project "S120_VECTOR_V46.zip"

Note In the menu “Drive Navigator“ of the “Servo“ object, up until now the speed
controller is supplied with the selected setpoint. Up until now, the "Extended
speed setpoint channel" has not been enabled in your configuration.
The reason for this is the applicable operating mode "Servo" in which the
setpoint channel is inhibited initially and must be enabled specifically.

1. If you wish to work with the Servo operating mode, select

>> Servo > Configuration> Configure DDS > Function module: Extended
setpoint channel

2. Save the change in your project, go online, transfer the project to the target
device and save the configuration permanently in a non-volatile fashion.

3. Check the result:

The drive navigator has been extended to include the “setpoint channel“
functionality.

4. Speed setpoint source:

As the speed setpoint source was previously directly interconnected from
TB30 to speed setpoint 2 (p1160), this interconnection must be
disconnected, and the speed setpoint interconnected from the TB30 to the
main setpoint (p1070) at the input of the setpoint channel.

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Training Document 11 - 12 Setpoint channel
Task To start, establish a simple function in order to test the operation of the drive.

1. Parameterize the following control commands using the switches on the

operator box.
• ON/OFF 1 via: DI 0
• OFF 2 via: DI 1
• OFF 3 via: DI 2
• Acknowledge via: DI 3

2. Parameterize the "Jog" function:

• Select jog via: DI 7
• Jog setpoint: 100 rpm

3. Test the function

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Training Document 11 - 13 Setpoint channel
Task Assign parameters to the motorized potentiometer function to perform the
following tasks:

1. Define the digital inputs to operate the motorized potentiometer MOP:

• MOP raise: DI 5
• Motorized potentiometer MOP lower: DI 6
• Select the automatic setpoint: DI 4

2. Enter the limits for manual operation:

• Control range: from -1000 rpm to +1400 rpm
• Ramp-up time RUT: 2s without rounding
• Ramp-down time RDT: 2s without rounding

3. Enter the ramp-up and ramp-down times for automatic operation:

• Ramp-up time RUT: 0s
• Ramp-down time RDT: 0s

4. Incorporate the motorized potentiometer into the setpoint channel:

• Motorized potentiometer output as main setpoint (p1070)
• Automatic setpoint from "Fixed speed setpoint" active (r1024)"

5. Test the parameterized functionality

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Training Document 11 - 14 Setpoint channel
Task Define the selection and values for the fixed setpoints as follows:

1. Enter the following setpoints:

• Fixed setpoint 0 0 rpm
• Fixed setpoint 1 +500 rpm
• Fixed setpoint 2 -500 rpm
• Fixed setpoint 3 +700 rpm

2. Parameterize the following binary logic operation to select the fixed

setpoints:
• Fixed setpoint 0 DI 5 = 0 DI 6 = 0
• Fixed setpoint 1 DI 5 = 1 DI 6 = 0
• Fixed setpoint 2 DI 5 = 0 DI 6 = 1
• Fixed setpoint 3 DI 5 = 1 DI 6 = 1

3. Test the parameterized functionality

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Training Document 11 - 15 Setpoint channel
Task Incorporate analog input 0 (AI0) as supplementary setpoint and scale the signal:

1. Incorporate the analog input:

• Analog input 0 (AI0) as supplementary setpoint:
• Switch-in or switch-out using: DI 12
• Sign reversal of the analog input using: DI 13

2. Scale the analog input as specified below. You can find the reference values
in p2000 – p2003.
• -10 V corresponds to -120 rpm
• +10 V corresponds to +240 rpm
With p2000 = 6000 rpm:
• -120 rpm corresponds to -2%
• +240 rpm corresponds to +4%
This means:
• -10V corresponds to -2%
• +10V corresponds to +4%

3. Test the function of the analog input.

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Training Document 11 - 16 Setpoint channel
Task Parameterize the following limits to protect the mechanical system against
overload, sudden acceleration and resonant frequencies.

1. Enter the following limits:

Speed range from -1500 rpm up to +2100 rpm

2. Parameterize the ramp-function generator:

• Ramp-up time: 2s
• Ramp-down time: 1s
• Ramp-down time for OFF3: 0.5s

3. Skip (suppress) the following speed range:

from +700 rpm to +750 rpm

4. Test the functionality by entering a setpoint via analog input 0 (AI 0).

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Training Document 11 - 17 Setpoint channel
Task In order to receive feedback regarding the drive status, route the following
signals to the binary and analog outputs.

1. Parameterize the important status signals to energize the LEDs of the

operator box:
• Operation enabled: DO 8
• No alarm: DO 10
• Ready to switch on: DO 9
• No fault: DO 11
• Negative speed: DO 15

2. Parameterize analog output 0 (AO 0) to display speed actual value nact:

• nact = - 1500 rpm -> AO 0 = 0 V
• nact = +1500 rpm -> AO 0 = 10 V

3. Parameterize analog output 1 (AO 1) to display the DC link voltage UDC link:
• UDC link = 0 V  AO1 = 0V
• UDC link = 500 V  AO 1 = +10 V

4. Test the parameterized functionality.

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Training Document 11 - 18 Setpoint channel
Task Back up your parameterization and archive your project.

1. Take appropriate steps to ensure that your online changes are still effective
even when the 24 V DC supply is reconnected to the CU320-2DP:

………………………………………………………………………………

2. Also ensure that your offline project at the PG/PC also has the changes
made online:

………………………………………………………………………………

………………………………………………………………………………
3. Save the current project and archive it under a different name:
>> Project > Archive ...

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Training Document 11 - 19 Setpoint channel
Learning Targets .............................................................................................................................. 2
LEDs on DRIVE-CLiQ components .................................................................................................. 3
BOP20 ............................................................................................................................................. 7
Diagnostics ...................................................................................................................................... 10
Faults and alarms ............................................................................................................................. 13
Trace function .................................................................................................................................. 18
Project comparison .......................................................................................................................... 21
Watch table ...................................................................................................................................... 26
Expert functions ............................................................................................................................... 27
Web server ...................................................................................................................................... 28
Exercise 1: Tracing bit tracks ........................................................................................................... 41
Exercise 2: Saving measurements ................................................................................................... 43
Exercise 3: Object comparison ......................................................................................................... 45
Exercise 4: Object comparison using the expert list .......................................................................... 47
Exercise 5: Watch table ................................................................................................................... 52
Exercise 6 – optional: Trace function ................................................................................................ 54
Exercise 7 – optional: Diagnostics in the power unit ......................................................................... 56
Übung 8: Diagnose über Webserver ................................................................................................. 57

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Training Document 12 - 1 Diagnostics
SITRAIN Page Course DR-S12-PM
Training Document 12 - 2 Diagnostics
 The individual states during the booting procedure are indicated by means of
the LEDs on the Control Unit.
• The duration of the individual states varies.
• If an error occurs, the booting procedure is terminated and the cause is
indicated on the LEDs. Remedial action in the event of an error: Insert the
appropriate memory card with the correct software and parameterization.
• Once the unit has successfully booted, all the LEDs are switched off briefly.
• Once the unit has been booted, the LEDs are driven via the loaded firmware.

RDY (Ready) Signals the operating status of the CU and the complete drive system

DP (Profibus DP) Only active during cyclic PROFIBUS DP communication and signals the status
of communication via the PROFIBUS DP onboard interface of the CU

OPT (Option board) Only active when the option board is inserted in the CU and signals the status of
this board.

BIOS This is boot loader 1 that is checked subsequently during booting of the CU.

Firmware The firmware for the CU and all connected DRIVE-CLiQ components is stored
on the CF card and is checked during initialization.

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Training Document 12 - 3 Diagnostics
RDY Betriebszustand - READY = GRÜN
Die Komponente ist betriebsbereit und die zyklische DRIVE-CLiQ-
Kommunikation findet statt oder die Control Unit wartet auf die
Erstinbetriebnahme.

DP Betriebszustand - PROFIdrive zyklischer Betrieb = GRÜN

Zyklische Kommunikation findet statt.

OPT Betriebszustand OPTIONBOARD = GRÜN

Option Board ist betriebsbereit.

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Training Document 12 - 4 Diagnostics
RDY Operating status – READY = GREEN
The component is ready and cyclic DRIVE-CLiQ communication takes place or
the Control Unit waits for first commissioning.

DP Operating status – PROFIdrive cyclic mode = GREEN

Cyclic communication takes place.

OPT Operating status OPTIONBOARD = GREEN

Option board is ready for operation.

CU loader The CU loader is located on the Control Unit. It corresponds to the BIOS
of a PC.

CU loader The CF loader is located on the CF card. It handles start-up of the Control Unit
and transfer of the required files after switch-on.

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Training Document 12 - 5 Diagnostics
Parameters The parameters are selected in the BOP20 using the number.
The parameter display is reached from the operating display by pressing
the "P" key.
Parameters can be searched for using the arrow keys.
The parameter value is displayed by pressing the "P" key again.
You can toggle between the drive objects by simultaneously pressing the
keys "FN" and the arrow keys.
You can toggle between r0000 and the parameter that was last displayed by
pressing the "FN" key in the parameter display.

Value display To switch from the parameter display to the value display, press the "P" key.
In the value display, the values of the adjustable parameters can be increased
and decreased using the arrow. The cursor can be selected using the "FN" key.

Prerequisite The corresponding access level must be set properly.

For our example, p0003 = 3.
Procedure:
• Press the "P" key.
• Press the arrow keys, select parameter p0013
• Press the "P" key.
• Press the arrow keys 4 times -> Select index 4
• Press the "P" key.
• Press the "FN" key 3 times -> Select hundred input position
• Press the arrow keys 3 times -> Enter 3 hundred value
• Press the "P" key.

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Training Document 12 - 7 Diagnostics
SITRAIN Page Course DR-S12-PM
Training Document 12 - 8 Diagnostics
SITRAIN Page Course DR-S12-PM
Training Document 12 - 9 Diagnostics
Message display Faults and alarms are displayed in the detail view of the workbench in the
STARTER. To do this, STARTER must be in ONLINE mode. You can then
activate display for alarms and messages in the "Alarms" tab in the detail view.
The fault and alarm display provides information about the origin and type of
faults and alarms that are present.

Level "Level" displays the type of information.

• Information: General information.
• Fault: General fault states (e.g. in the communication to the drive).
• Alarm: Fault states relating to the technology object.

Time The time and date stamp of the fault or information/alarm is displayed.

Source The device or technology object where the fault or information/alarm has
occurred is displayed.

Message The fault or information/alarm text is displayed in plain text. The fault or alarm
text generally contains additional information.
For a description of the additional information, please refer to the online help.

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Training Document 12 - 10 Diagnostics
Faults Faults are indicated with Fxxxxx (fault) and generally result in a fault response.
• Must be acknowledged once the cause has been remedied.
• Status via Control Unit and LED RDY.
• Status via PROFIBUS status signal ZSW1.3 (fault active).
• Entry in the fault buffer.

Alarms Alarms are identified by Axxxxx (alarm).

• They have no further effect on the drive unit.
• The alarms are automatically reset once the cause has been remedied. No
acknowledgement is required.
• Status via PROFIBUS status signal ZSW1.7 (alarm active).
• Entry in the alarm buffer.
General properties
• Triggering on selected messages possible
• Initiation of external alarm/fault possible via an external signal.
Acknowledgement
of faults The list of faults and alarms specifies how each fault is acknowledged after the
cause has been remedied.
• Acknowledge faults with "POWER ON"
 Switch the drive on/off (POWER ON)
 Press the RESET button on the Control Unit
• Acknowledge faults with "IMMEDIATE"
 Using the PROFIBUS control signal
 Using an external input signal
 Via BOP/AOP
• Acknowledge faults with "PULSE INHIBIT"

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Training Document 12 - 11 Diagnostics
Reaction A variety of reactions are possible for faults, e.g.: OFF1, OFF2 or OFF3.
The default reaction is indicated. Reparameterization can be used to select a
fault reaction from the options stated in brackets.

Acknowledgement Faults can be acknowledged on one drive object or on all drive objects as
follows:
• Acknowledging by setting parameter: p3981 = 0 --> 1
• Acknowledging via binector inputs:
 p2103 BI: 1. Acknowledge faults
 p2104 BI: 2. Acknowledge faults
 p2105 BI: 3. Acknowledge faults
• Acknowledging via a PROFIDRIVE control signal: STW1.7 = 0 -> 1 (edge)
• Acknowledge all faults via p2102 BI: Acknowledge all faults
All of the faults on all of the drive objects of the drive system can be
acknowledged using this binector input.
Note:
• These faults can also be acknowledged by a POWER ON operation.
• If this action has not eliminated the fault cause, the fault will continue to be
displayed after acknowledgment.

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Training Document 12 - 12 Diagnostics
Fault/alarm memory Each drive object has its own fault memory for faults and alarms, which is
stored in non-volatile memory. This fault memory has a length of 64 lines, which
are displayed in the detail view via Diagnostics > Alarm history.

Fault memory The fault memory is 64 lines in length and has the following structure:
• Current fault: Lines 0 to 7 with parameters r945[0] … r945[7]
• 1st acknowledged fault: Lines 8 to 15 with parameters r945[8] … r945[15]
• …
• 7th acknowledged fault: Lines 56 to 63 with parameters r945[56] … r945[63]

Actual fault The currently active faults that have neither been rectified nor acknowledged.

Acknowledged fault When the cause of the fault has been rectified and the fault has been
acknowledged, these fault alarms are moved to the next acknowledged fault
case. It is therefore possible to save up to 7 previous fault cases in addition to
the current fault case. If a further fault case arises, the previous contents of the
7th acknowledged fault are lost. This behavior corresponds to that of a shift
register with 8 stages.

Alarm memory The alarm memory is 64 lines in length and has the same structure as the fault
memory.

Active alarms Lines 7 to 0 contain the currently active alarms, whereby the latest alarm is in
line 7 and the oldest active alarm is shown in line 0.

Alarm history The alarms that have returned to normal are shown in lines 8 to 63 with the
latest alarm in line 8 and the oldest in ascending order from line 9.
If the alarm memory is full up to line 63 and another alarm is output, these
entries are shifted by one line such that the old contents of line 63 are lost.

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Training Document 12 - 13 Diagnostics
Fault response Every fault is assigned to a predefined fault response. This is assigned in the
online help for the respective fault. In some cases, it is also possible to define
another fault response.
For this purpose, the fault code must be specified in parameter p2100[x] and the
required fault response in parameter p2101[x].
Up to 20 fault codes can be entered and different fault responses can be
defined for each. The extent to which these changes affect other drive objects
and functions should be clarified with the person responsible in Siemens
Customer Support.

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Training Document 12 - 14 Diagnostics
Alarm or fault If a response defined as an alarm should trigger a fault with a fault response,
you can enter the alarm code in parameter p2118[x] and select the entry "Fault"
in the corresponding p2119[x] parameter. A total of 20 changes are possible for
each drive object.

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Training Document 12 - 15 Diagnostics
Acknowledgement The acknowledgement response can also be changed in some circumstances.
To do this, you must enter the fault code in parameter p2126[x] and select the
acknowledgement response in the corresponding p2127[x] parameter.

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Training Document 12 - 16 Diagnostics
Trigger word Parameter p2128[x] can be used to individually assemble a trigger word with up
to 16 faults and alarms. A "1" signal will then be output in parameter r2129 at
the respective bit position as soon as the associated fault or alarm has
occurred.
This means that triggering is possible in response to a specific fault or alarm.

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Training Document 12 - 17 Diagnostics
Triggering By assigning trigger word parameters for the faults and alarms, it is possible to
start a trace whenever a particular fault/alarm occurs.

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Training Document 12 - 18 Diagnostics
Upload curve Click Upload curve to load the device trace curves recorded and saved in the
target system to the STARTER. This function can be used, for example, if a
trace recording in the target system was started by a user program or if certain
error states occur.
While the device trace is being recorded, a connection between the STARTER
and the target system is not necessary. These recorded curves can be loaded
to the target system when required. Only the last measurement can be loaded.

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Training Document 12 - 19 Diagnostics
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Training Document 12 - 20 Diagnostics
Project comparison Project comparison is activated in Starter using the button.

This allows difference in the project to be shown:

• Differences in the topology
• Differences in the function modules
• Differences in the load parameters
• Indication that drive objects are missing.

Offline/online data Differences in the load parameters are indicated by the following symbol:
By double-clicking this button, the parameters can be displayed with their
differences in a detail view.

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Training Document 12 - 21 Diagnostics
Detail comparison The different parameters of this drive object are displayed in this view.

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Training Document 12 - 22 Diagnostics
Parameter comparison Within a drive object, differences between parameters can also be determined
using the comparison function of the expert list.

Online/offline data The question often arises as to what differences exist in the parameters
between the online and offline data.. This can be established in Starter from the
expert list using the following button:
You can suppress the read parameters, if required, by setting the display filter.
Parameters that differ are displayed with a red background.

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Training Document 12 - 23 Diagnostics
Parameter comparison Within a drive object, differences between parameters can also be determined
using the comparison function of the expert list.

Online/offline data The question often arises as to what differences exist in the parameters
between the online and offline data.. This can be established in Starter from the
expert list using the following button:
You can suppress the read parameters, if required, by setting the display filter.
Parameters that differ are displayed with a red background.

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Training Document 12 - 24 Diagnostics
Comparison result The result of the parameter comparison can be saved and processed in the
following way:
• Save as user-defined parameter list
• Save as user-defined value list
• Save as executable script on the source object …
User-defined
parameter list Contains the parameter numbers for all parameters with differences, in
accordance with the filter function selected
User-defined
value list Contains the parameter numbers and the assigned values complete with their
physical dimensions, e.g.:

From an opened value list, the parameters saved there can be transferred
selectively back to the expert list.

Executable script A script file is generated for this object that can be executed offline or online.
The script file can be expanded and changed as required. Exporting and
importing is also possible. This means that the script file is accessible to other
drive objects.

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Training Document 12 - 25 Diagnostics
Watch table In order to make working with lists more transparent and easier to configure and
also to be able to display larger quantities of data in a structure, you have
various options for laying out the lists and adapting them to the relevant
conditions.
Create watch
table To create a watch table, proceed as follows:

1. Mark the MONITOR element in the project navigator.

2. Select
>> Insert > Watch table in the menu.

3. Enter the name of the watch table.

4. Click OK to confirm.

Fill the watch table There are several ways of filling a watch table: You can edit directly in the watch
table, you can insert variables using copy&paste or you can take these over
directly from other lists or from the program editors:

1. In the project navigator, select the element whose variables are to be loaded
into the watch table. The variable tables are displayed in the symbol
browser.

2. In the symbol browser, select the lines with the variables which are to be
transferred to the watch table by clicking the line numbers.

3. In the context menu (right-click), select

>> Add to watch table > <watch table name>

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Training Document 12 - 26 Diagnostics
Parameter List The data entered in the screens is stored in SINAMICS in parameters.
Each object has its own parameter list.

Expert List The parameters for the individual objects can be checked/modified via the
expert list.
You can access the expert list after selecting the object via the Expert List
context menu.
Select object > right mouse click > Expert > Expert list

Access level Various access levels for the BOP

can be set in the expert list. A certain number of parameters are shown as
appropriate to the authorization.
All parameters with access level "Expert" are shown in the expert list. Access
level 4 "Service" is intended for the SIEMENS service employees and is
password-protected.

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Training Document 12 - 27 Diagnostics
Web server A web server is implemented in the SINAMICS runtime as of Version V4.6.

Secure connection You can access the web sites of the SINAMICS S120 via encrypted transfer.
The protocol is called HTTPS. You can also implement an authorization using
certificates. For information on authorization, please see the SINAMICS
documentation.

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Training Document 12 - 28 Diagnostics
Login Use "SINAMICS" without password to log in.
An administrator login is also available; the password can be changed on the
"Setup" page prior to first commissioning.
The STARTER configuration has priority.

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Training Document 12 - 29 Diagnostics
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Training Document 12 - 30 Diagnostics
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Training Document 12 - 31 Diagnostics
Faults / Alarms The icons are color-coded:
• Yellow – Alarm
• Red – Fault
• Green – OK

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Training Document 12 - 32 Diagnostics
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Training Document 12 - 33 Diagnostics
Parameter lists When you are logged on as "Administrator", you can create parameter lists and
sort and modify them.
As administrator, you can also change values. When you are logged on as
"SINAMICS", you can monitor the parameter lists. If the administrator has
assigned the appropriate rights to the "SINAMICS" user, you can use this login
to make changes to parameter lists and parameters.

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Training Document 12 - 34 Diagnostics
Update Data You create a zip archive with
• the firmware,
• the project (load to file system) or
• both.
To do this, perform a "Download to file system" in the folder that contains the
firmware.

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Training Document 12 - 35 Diagnostics
Application You can store backup files in a folder on the CF card (e.g. "Backup").
The data are located in the "Install" folder on the CF card.

Login The standard login "sinamics" with the password "sinamics" serves as login.

Parameter You can deactivate the FTP server by setting parameter p8908 to "0".

Note A search is made for firmware or project data directly in the zip archive stored at
the top directory level during startup of the SINAMICS S120.
The active configuration/parameterization is overwritten directly with the
contents of the zip archive.

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Training Document 12 - 36 Diagnostics
User administration If the SINAMICS S120 Version V4.6 or higher is at factory settings, you can also
handle user administration in the web server. Two users are available for
activation. Please always assign a password to an administrator! You can use
the "sinamics" login with or without password.

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Training Document 12 - 37 Diagnostics
HTTPS You set up an SSL-encrypted tunnel.
The data exchanged are encrypted.
You can import a certificate to do this.
Browser Please activate
"SSL 2.0" in the browser.

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Training Document 12 - 38 Diagnostics
Industrial Security You can use SCALANCE S products to protect your machine easily and
scalably, while nevertheless accessing the components via the Internet.

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Training Document 12 - 39 Diagnostics
Safety information Please note that:
• The course instructions have been produced for:
 A course held by a course leader
 Activities carried out on special training equipment
• The training equipment is operated under laboratory conditions.
In case of doubt, always ask your course leader – particularly when handling
components that carry electrical current or which can move.
• When carrying out work on equipment, the safety information in the
associated product documentation must always be observed!
The training documents alone are not sufficient.

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Training Document 12 - 40 Diagnostics
Task Activate a trace recording for a pending fault!

1. Open the archived project "S120_servo_V47", load the data to the drive and
test the movement of both motors.

2. Switch on the DI3 and DI7 switches on the operator box and configure
switch DI8 for "Servo_02" to simulate an external fault F7860.

3. Enter the fault code "7860" (external fault 1) in p2128[3].

When this event occurs, bit 3 in r2129 changes from 0 to 1.

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Training Document 12 - 41 Diagnostics
 4. For trace 1, as trigger criteria select "bit pattern", and as trigger source,
parameter r2129 and a pre-trigger of 90% of the recording time.

5. Then, using the "bin..." button, define the bit mask and the bit pattern, so that
the trace is triggered when F7860 (external fault 1) occurs.

6. Start the trace recording and switch the drive on:

 Trace 1 waits for the trigger signal.

7. Trigger fault message F7860 by switching off switch DI8 (DI8 = 0):
 The signal recording is started.

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Training Document 12 - 42 Diagnostics
Task Save the measurements that you have made. Proceed as follows:

1. Open the "Measurements" tab.

2. Under this tab, press the "Save measurements" button.

3. Allocate a file name and define a storage location:

>> Measurements.trc > Save

4. Now select the measurements to be saved, and exit this window with >> OK.

Note In this way, you can save all of the measurements in a common file, or by
pressing the "Save measurements" button several times, you can save the
measurements in different files.

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Training Document 12 - 43 Diagnostics
Task If you wish to save measured values in a list form, then proceed as follows:

1. In Starter, open the dialog box to create an export file:

>> Trace > Measurement > Export measurements

2. Select a file format, allocate a file name and define the storage location:
>> Measurements.csv > Save

3. Now select the measurements to be saved, and exit this window with >> OK.

4. After they have been successfully exported, the measurements are now
available in a list form for archiving or for further processing.

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Training Document 12 - 44 Diagnostics
Task Two similar drive units should be investigated regarding their differences.
Therefore, create two different drive units and compare these:

1. Go into the offline mode.

2. In your "S120<-servo_v46" project, create a 2nd drive unit,
Sinamics_S120_1:
>> Right mouse click on Sinamics_S120 > Copy
>> Right mouse click on S120_V44 > Paste
3. Allocate the Sinamics_S120_1 name
4. In the drive unit Sinamics_S120_1, delete the object TB30_04:
>> Open CU_S_004 > TB30_04 > Delete
5. Now set the open BICO connections to the factory settings
6. Start the object comparison:
>> Button "Object Comparison" >
Comparison partner A: Sinamics_S120
Comparison partner B: Sinamics_S120_1
> Start Comparison
7. Interpret the result:
Topology:

………………………………………………………………………………
Objects:

………………………………………………………………………………
Load parameters:

………………………………………………………………………………
8. Delete the SINAMICS_S120_1 device again from the project:
>> Right mouse click on Sinamics_S120_1 > Delete

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Training Document 12 - 45 Diagnostics
Task With the online connection to your target system, you want to determine the
differences between your offline project and the data in the drive. Make a
comparison between your offline project and the target system:

1. From your project, go online with the drive unit

2. Perform a "Download to PG" if the parameter assignment differs.

3. Start the object comparison.

4. Interpret the result:

• Topology:
• Objects:
• Download parameters:

5. Now, in the online mode, in SERVO_02 change the following parameters

(without backup RAM to ROM) e.g.:
• OFF 1 ramp-down time: p1121 = 15.0 s
• OFF 3 ramp-down time: p1135 = 5.0 s

6. Start the object comparison again:

7. Result:

………………………………………………………………………………

8. Observe how the parameter changes in the detailed comparison of the

download parameters are displayed.

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Training Document 12 - 46 Diagnostics
Task In the detailed comparispon the two paraemters casn be seen. Using the filter it
may help to have a better view on the parameters.

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Training Document 12 - 47 Diagnostics
Task Save the comparison results for "Servo_02" in various file formats for
subsequent use:

1. The result of the comparison can bes aved in diferent ways:

>> Save comparison result …
• as user-defined parameter list (in the format *.cdl)
• as user-defined value list for the value column “Servo_02_Online“
(in the format *.xml)
• as executable script at the "Servo_02" object in the "SCRIPTS" folder
with the name “Script_1" (in the format *.txt)

2. In the first step select “user-defined parameter list”. After saving the list can
be opened in the expert list.

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Training Document 12 - 48 Diagnostics
Task In the next step the comparison should be saved in a user defined value list.
Test the principle of operation of a script file, by using both parameters of script
file "Script_1" also for "Servo_03":

1. To do this, save the parameter in a “user defined list” and save it on the
desktop.

2. The file can be opened and the parameters can be checked.

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Training Document 12 - 49 Diagnostics
Task Test the principle of operation of a script file, by saving the result of the
comparison in an executable script.

1. To do this, create a script file by saving the parameters in an “executable

script at source abject drive 1”. The script is generated.

2. In the directory drive object you find a directory for the sripts. There the
generated scipt file is saved.

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Training Document 12 - 50 Diagnostics
 1. Open the script file and change the values of the parameters and save the
file.

2. The script file can be executed by:

>> With the right mouse key > Accept and execute

3. Check as to whether the two values from the script file have been transferred
into the Expert list of the driveobject.

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Training Document 12 - 51 Diagnostics
Note Watch tables provide an efficient and transparent way of combining, monitoring
and where relevant, controlling parameters from a wide range of Sinamics drive
units within the same project in a common table.

Task Create a common watch table for the two "Servo_02" and "Servo_03" drives:

1. Open the Expert lists for the "Servo_02" and "Servo_03" drives.

2. In your project, open the "Monitor" directory

3. Double-click on "Insert watch table"

4. Accept the recommended name "Watch_table_1" and acknowledge the

opened window with "OK".

5. In the Expert list, select those parameters that you wish to transfer into the
watch table:
• p2900: Fixed value 1
• r63: Speed actual value
• p1121: Ramp-function generator ramp-down time
• p1135: OFF3 ramp-down time

6. >> right mouse key > Accept in watch table > Watch_table_1

7. Establish an interconnection between p2900 and speed setpoint 2 (p1160).

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Training Document 12 - 52 Diagnostics
Task Test the watch table and control the drive parameters using the watch table:

1. Open Watch_table_1.

2. Activate the "Control value" column.

3. Here, enter suitable values for parameter p2900 and accept these using the
"Accept control values in the online data".

4. Accept these control values using the "Save control value set".

5. Enter a name for the control value set and confirm with "OK".

This means that you can use these control values at any time.

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Training Document 12 - 53 Diagnostics
 Encoder signals can, in principle, also be recorded using the trace function.
However, some supplementary conditions are still relevant here.
• The access level must be set to Level 4 (Service).
• The trace cycle and encoder increments must match; otherwise, the pulse
will not be detected.
• In many cases, the encoder signals are displayed as double-words and must
be interpreted accordingly.

Task Record the encoder signal.

1. Open the expert list of the drive object.

2. Use parameter p496 to select which signals are to be entered in the

following parameters:
• p497
• p498
• p499

3. Open the trace tool and record the parameter.

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Training Document 12 - 54 Diagnostics
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Training Document 12 - 55 Diagnostics
Current transducers SINAMICS acquires the current for each motor phase by means of a current
transducer. These current transducers measure the current indirectly using the
Hall effect, so an offset can occur as the current transducer ages. SINAMICS
therefore saves the offsets for the phase currents in parameters r69[3], r69[4]
and r69[5] that the associated current transducer measures despite a pulse
inhibit.

This compensation results in the actual flowing phase current being indicated in
parameters r69[0], r69[1] and r[2].

As soon as the current offset overshoots a predefined threshold, a ground fault

is indicated.

Task Check the phase current offset when a pulse inhibit is present for a motor object
and enter this value as follows:

r69[3] : ……………………………………..

r69[4] : ……………………………………..

r69[5] : ……………………………………..

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Training Document 12 - 56 Diagnostics
Webserver Eine Diagnose kann auch über den integrierten Webserver durchgeführt
werden.
Verbinden Sie die Schnittstelle des PG mit der LAN-Schnittstelle (X127) der
CU320-2 DP über ein Ethernet-Kabel.
Rufen Sie den Internet-Explorer auf und geben Die IP-Adresse der LAN-
Schnittstelle ein (default: 169.254.11.22).
Die Startseite wird angezeigt. Der Account lautet „SINAMICS“ ohne Passwort.
Kontrollieren Sie die Diagnosemeldungen und erstellen ggf. eine
Parameterliste.

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Training Document 12 - 57 Diagnostics
Learning Targets .............................................................................................................................. 2
Positioner application ....................................................................................................................... 3
Traversing profile ............................................................................................................................. 4
Rotary and linear axes ..................................................................................................................... 5
Operating modes .............................................................................................................................. 6
Jog operating mode ......................................................................................................................... 7
Homing mode ................................................................................................................................... 8
Direct setpoint specification mode/MDI ............................................................................................. 10
Traversing blocks mode ................................................................................................................... 11
Integration of EPOS in the basic functionality ................................................................................... 13
Basic positioner and position controller ............................................................................................. 14
Control panel ................................................................................................................................... 18
BICO interconnections ..................................................................................................................... 19
Diagnostic information ...................................................................................................................... 21
Exercise 1: Configuring the basic positioner ..................................................................................... 23
Exercise 2: Set home position .......................................................................................................... 25
Exercise 3: Traversing blocks ........................................................................................................... 26

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Training Document 13 - 1 Basic positioner
EPOS EPOS = Basic positioner
Depending on the EPOS operating mode, EPOS supplies the position controller
with the required position setpoint "s".

Position controller This has the task of establishing the position setpoint received from EPOS. The
position controller receives the actual position value from the selected encoder.
The position controller supplies the speed setpoint "n" for the series-connected
speed controller.

Setpoint input Depending on the selected operating mode, EPOS calculates the position
setpoint "s" for the position controller.
Actual value
acquisition The current actual position value is supplied to the position controller via the
assigned encoder measurement system.

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Training Document 13 - 2 Basic positioner
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Training Document 13 - 3 Basic positioner
Positioning A positioning request is configured by specifying
• the target position
• the velocity
• the acceleration and
• the deceleration

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Training Document 13 - 4 Basic positioner
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Training Document 13 - 5 Basic positioner
MDI Rotary indexing table in MDI
Direct transfer of the position parameters to the higher-level control:
Target position, velocity, acceleration, deceleration

Basic handling For example, in the traversing block mode via pre-stored motion sequences for
easy and fast handling. Traversing blocks contain details of:
Target positions, velocities, accelerations, decelerations

Flying positioning Position conveyor belts dynamically and accurately with the "Homing" mode.

Stacker unit High flexibility in MDI mode by specifying target position, velocity, acceleration,
deceleration.

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Training Document 13 - 6 Basic positioner
Jog In "Jog" mode, both functions "Position controlled jogging" and "Incremental
jogging" are available. The selection is effected via the two digital inputs "Jog 1"
and "Jog 2".
Position controlled
jogging Traversing takes place with the assigned setpoint velocity as long as the enable
is active for this operating mode.
Incremental
jogging Traversing takes place with the assigned setpoint velocity as long as the enable
is active for this operating mode until the number of position increments has
been traversed. If the enable is removed prematurely, the axis is halted at the
current position.

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Training Document 13 - 7 Basic positioner
homing After a machine has been switched on, for positioning, the absolute dimension
reference must be established to the machine zero. This procedure is referred
to as referencing ("homing"). The following referencing types are possible:
• Setting the home position (all encoder types)
• With incremental encoder
 Active referencing
 With reference cam and encoder zero mark
 With encoder zero mark
 With external zero mark
 Passive/flying referencing
• With absolute encoder
 Absolute encoder adjustment
 Passive/flying referencing
For all referencing types, a connector input must be provided to specify the
home position coordinates. However, to permanently enter the home position
coordinate, an adjustable parameter for this quantity is also required. As
standard, this adjustable parameter p2599 is interconnected to connector input
p2598.

Home position setting The home position can be set by a 0/1 edge at the "Set home position" binector
input. The current actual position of the drive is set here as the home position
using the coordinate specified by the "Home position coordinate" connector
input. The setpoint is adjusted accordingly.

Flying With flying referencing, a 0/1 edge at the binector input can make a correction to
the actual position during positioning and thereby compensate for inaccuracies
in actual value acquisition. This increases the load-side positioning accuracy.

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Training Document 13 - 8 Basic positioner
 Absolute encoders have to be adjusted during commissioning. After the
machine has been switched off, the position information of the encoder is
retained.
When "Perform absolute value calibration" is entered, an offset value (p2525) is
determined using the home position coordinate. This is used to calculate the
actual position value. Performance of adjustment is confirmed in the screen.
The offset of the encoder adjustment should be saved in a non-volatile fashion
(RAM to ROM) to permanently save it.

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Training Document 13 - 9 Basic positioner
 With the "Direct setpoint specification/MDI" mode, you can use the predefined
dynamic values (velocity, position, acceleration and delay) to perform absolute
and relative positioning. Positioning.
Absolute
positioning After setpoint transfer, the basic positioner traverses to the absolute position
specified in length units (LU). After the next setpoint transfer, this absolute
position is approached, or if it has already been reached, it is maintained.

Relative
positioning After setpoint transfer, the basic positioner traverses the relative path specified
in the length units (LUs). After the next setpoint transfer, this path is traversed
again.

Setpoint transfer A positioning task is not performed until setpoint transfer is triggered with a
rising edge.

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Training Document 13 - 10 Basic positioner
 A table top veneered on both sides must be drilled using a milling tool. Describe
the vertical motion of the milling tool with a traversing block table. The traversing
path is divided into positions A, B, C, D and E and is described with the
following traversing profile:

Path A  B: 6-times velocity (pos. direction)

Path B  C: 1-times velocity (pos. direction)

Path C  D: 4-times velocity (pos. direction)

Path D  E: 1-times velocity (pos. direction)

In position E: 500 ms waiting

Path E  A: 6-times velocity (neg. direction)

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Training Document 13 - 11 Basic positioner
Traversing blocks Max. 64 traversing blocks per drive

Index No. "-1": Inactive traversing block

0 … 63: Active traversing block

Job Task within the traversing block, e.g. positioning, waiting, goto, …

Parameter This is valid in accordance with the task, e.g.:

WAIT 1000 ms or
GOTO 0 (jump to traversing block No. 0)

Mode Valid according to the job, e.g.:

POSITIONING ABSOLUTE or
POSITIONING RELATIVE

Position Valid according to the job POSITIONING, e.g.:

POSITIONING ABSOLUTE to position 1000000 LU or
POSITIONING RELATIVE by 50000 LU

Advance Specifies the block change criterion for this positioning job, e.g.:
CONTINUE_WITH_STOP,
CONTINUE_FLYING,
CONTINUE_EXTERNAL,
CONTINUE_EXTERNAL_WAIT or
CONTINUE_EXTERNAL_ALARM

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Training Document 13 - 12 Basic positioner
Connecting When the function "Basic positioner" is activated, both the basic positioner and
the position controller are enabled.

They are connected by the system with the speed controller and current
controller in the correct order. This means that the typically used 3-level
cascade "Position controller – Speed controller – Current controller" is also
available in SINAMICS S120 All the BiCo connections required here are
implemented automatically.

Basic positioner Depending on the selected operating mode, the basic positioner calculates the
position setpoint and supplies this to the series-connected position controller on
its setpoint input.

Position controller The position controller calculates the speed setpoint from the position setpoint
obtained from the basic positioner and the actual position value obtained from
the encoder system which it then supplies to the series-connected speed
controller on its setpoint input.

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Training Document 13 - 13 Basic positioner
Configuration
1. Go offline
2. Inside the desired motor object, select  Configuration
3. Press the "Configure DDS …" button
4. Select the basic positioner (EPOS) and go through the DDS configuration as
usual using the "Next" button

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Training Document 13 - 14 Basic positioner
Selection The converter must know which encoder has supplied the actual position
values. Select the motor encoder as position measurement system here
(indirect position measurement system).

Note The training case does not have an additional position controller; it simply
accepts the actual position value from the motor encoder, so it has no direct
position measurement system.

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Training Document 13 - 15 Basic positioner
Mechanics For the drive to approach positions autonomously without the higher-level
controller, it must calculate actual position values from the encoder signals.
When the data set is configured, the relationship between the machine position
and the encoder signal must be specified.

LU (Length Unit) With SINAMICS S120, the position controller and the basic positioner work with
a dimensionless variable LU (Length Unit).
For the linear encoder, the relationship between the physical variable and the
neutral length unit LU is configured with the parameter p2503 (LU / 10 mm).
Example:
Linear scale, 10 mm must represent 1 μm (i.e. 1 LU = 1 μm)
 p2503 = 10000
For a spindle pitch of 10 mm/load revolution (corresponding to
10,000 LU/load revolution), 1 LU = 1 µm resolution.
Conclusion of
DDS configuration Close the DDS configuration now using the "Next" button, switch to Online and
load the data for your EPOS into your drive.

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Training Document 13 - 16 Basic positioner
Mechanik Soll der Antrieb ohne übergeordnete Steuerung eigenständig Positionen
anfahren können, so muss er aus den Gebersignalen Lageistwerte berechnen.
Deshalb muss bei der Konfiguration des Datensatzes die Relation der
Maschinenposition zu dem Gebersignal vorgegeben werden.

LU (Length Unit) Bei Sinamics S120 arbeiten der Lageregler und der Einfach-Positionierer mit
einer dimensionslosen Größe LU (Length Unit).

Beim linearem Geber wird der Zusammenhang zwischen der physikalischen

Größe und der neutralen Längeneinheit LU über den Parameter p2503
(LU /10mm) konfiguriert.

Beispiel:
Linearmaßstab, 10 mm sollen auf 1 μm aufgelöst werden (d. h. 1 LU = 1 μm)
 p2503 = 10000
Bei einer Spindelsteigung von 10 mm/Lastumdrehung (entspricht
10.000 LU/Lastumdrehung) bedeutet 1 LU = 1 Micrometer Auflösung.
Abschluss der
DDS-Konfiguration Schließen Sie nun die DDS-Konfiguration mit der Weiter-Schaltfläche ab, gehen
Sie ONLINE und laden Sie die Daten Ihres EPOS in Ihren Antrieb.

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Training Document 13 - 17 Basic positioner
Control panel In addition to specifying the speed, the control panel can also support
commissioning of the "Basic positioner" function for a drive with positioning
functionality.

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Training Document 13 - 18 Basic positioner
Interconnection The operating modes must be adapted to the application using interconnections.
Each mode provides two screens to do this:
• Digital signals for interconnecting binectors
• Analog signals for interconnecting connectors
A third screen is also provided for diagnostics

Digital signals Depending on the operating mode, different digital signals are offered for further
interconnection of the inputs and outputs.
Functions are initiated or selected via the inputs; the feedback signal to the
application is issued via the outputs.

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Training Document 13 - 19 Basic positioner
Analog signals Depending on the operating mode, different signals are offered for further
interconnection.

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Training Document 13 - 20 Basic positioner
Diagnostics The "Diagnostics" screen lists the diagnostic information that is important for
this operating mode.

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Training Document 13 - 21 Basic positioner
Prerequisites Status of the device:
• First commissioning completed

Safety information Please note that:

• The course instructions have been produced for:
 A course held by a course leader
 Activities carried out on special training equipment
• The training equipment is operated under laboratory conditions.
In case of doubt, always ask your course leader – particularly when handling
components that carry electrical current or which can move.
• When carrying out work on equipment, the safety information in the
associated product documentation must always be observed!
The Training Documents alone are not sufficient.

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Training Document 13 - 22 Basic positioner
Preconditions A project with a "Servo" drive object. For this purpose, use the
"S120_SERVO_1.zip" project that you archived on the hard disk.

Task You will implement a basic positioning task using the blue motor ("Servo_03") of
your exercise unit. Configure this drive as a basic positioner:

1. Go online and select "Servo_03":

>> Configuration > Configure DDS…

2. Run through the configuration of the "Servo_03" drive object with the
following features:
• Basic positioner
• Power, motor and encoder data (already set as for the closed-loop speed
control)
• Gear ratio: Load revolutions/motor revolutions = 1/1
• Position resolution = 1000 LU per load revolution (LU = Length units)
• Free telegram configuration with BICO

3. Save your project.

4. Online: Download the extended project to the target device and ensure that
the data are consistent in all memory locations used.

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Training Document 13 - 23 Basic positioner
Task Test the drive using the control panel in the speed-controlled and position-
controlled mode

1. Under SERVO_03, select the control panel:

>> SERVO_03 > Commissioning > Control panel
2. Use this to test the functions of the "blue axis", initially with the "speed
setpoint input".
3. Now select the control panel function "Basic positioner"
4. Assume control priority
5. Set the required enable signals
6. Select the EPos function, "Jogging"
7. Switch on the axis
8. Issue the jog command using the mouse. As long as you issue the jog
command, the axis moves with the assigned acceleration (a) and the
specified velocity (v).
9. Withdraw the jog command
10. Switch off the axis
11. Give up control priority.

Note As, during the configuration, a rotation 1000 LU (position resolution 1000 LU/U)
was assigned, and input of e.g. v = 600 [1000 LU/min] corresponds to a speed
of 600 rpm.

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Training Document 13 - 24 Basic positioner
Task On the exercise equipment, it is not possible to realize a reference point
approach, therefore the basic positioner must be set to a position of 0 via an
externally switched signal:

1. Under the "Servo_03" drive object, open referencing/homing:

>> Technology > Basic positioner > Homing >
Homing/configuration > Digital signals.

2. Assign switch DI 8 to the function "Set reference point".

3. Go to the tab "Homing/diagnostics“

4. Note the following feedback messages:

• Reference point set [ ] yes [ ] no

• Position setpoint/actual position: ……………………………………..

5. Switch on the axis (DI4 = 1), and briefly enter the command
"Set reference point" (DI8 = 1).

6. You obtain the following results as feedback signal:

• LED "Reference point set" = lit/on
• Position setpoint / position actual value = 0

Note Without renewed setting or approaching a reference point, the axis position that
you have selected is considered to be the "zero" position; for all of the position
commands, it is valid as the reference position.

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Training Document 13 - 25 Basic positioner
Task For your positioning task, generate a simple traversing program according to the
example described above:

1. Go to the function
>> Traversing blocks > Traversing blocks/configuration > Digital signals

Make the following interconnections:

• DI 9 = Activate traversing task
• DI10 = Intermediate stop (0 signal)
• DI11 = Reject traversing task (0 signal)

2. Go to the function >> Traversing blocks

There, program the 5 traversing blocks corresponding to the

recommendation above.

3. Activate the traversing task with:

• DI10 = 1
• DI11 = 1
• DI 9 = 0  1
Monitor how the axis tracks the parameterized traversing blocks.

Note The following options are applicable in order to stop the axis that is now in the
endless operating mode:
• Interrupt the traversing task: DI10 = 0
• Reject the traversing task: DI11 = 0
• Switch off the drive: DI4 = 0 (fault message)

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Training Document 13 - 26 Basic positioner
Learning Targets .............................................................................................................................. 2
Safety Integrated with SINAMICS ..................................................................................................... 3
Background – safety functions .......................................................................................................... 4
Safety concept within the EU ............................................................................................................ 5
The European Machinery Directive ................................................................................................... 6
The relevant standards ..................................................................................................................... 7
The European Machinery Directive ................................................................................................... 8
What hazards can occur? ................................................................................................................. 10
Risk assessment .............................................................................................................................. 11
What does a safety level state? ........................................................................................................ 12
"Safe" machine ................................................................................................................................ 13
Safety system .................................................................................................................................. 14
Overview ......................................................................................................................................... 17
S120 safety functions ....................................................................................................................... 18
Onboard terminals ............................................................................................................................ 22
Safe Torque Off (STO) .................................................................................................................... 24
Safe Stop 1 (SS1) ............................................................................................................................ 26
Safe Brake Control (SBC) ................................................................................................................ 27
Selection of the basic safety functions .............................................................................................. 28
Configuration of the basic safety functions ........................................................................................ 29
Activation of the basic safety functions ............................................................................................. 31
Acceptance test ............................................................................................................................... 32
Acceptance test for changes ............................................................................................................ 37
Exercise 1: "Safe Torque Off" (STO) function ................................................................................... 40
Exercise 2: "Safe Stop 1" (SS1) function .......................................................................................... 43

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Training Document 14 - 1 Drive based safety integrated
SITRAIN Page Course DR-S12-PM
Training Document 14 - 2 Drive based safety integrated
SITRAIN Page Course DR-S12-PM
Training Document 14 - 3 Drive based safety integrated
Objective Manufacturers and operators of technical equipment and products are
responsible for safety. This means that plants, machines and other technical
equipment must be made as safe as possible in accordance with the latest
technology.
Safety systems are designed to minimize potential hazards for both people and
the environment by means of suitable technical equipment, but without
restricting industrial production and the use of machines more than necessary.
The protection of people and the environment must be assigned equal
importance in all countries, while it is important that rules and regulations that
have been internationally harmonized are applied. This is also intended to avoid
distortions in the competition due to different safety requirements in different
countries.

Functional safety From the perspective of the object to be protected, safety is indivisible. The
causes of hazards and therefore also the technical measures to avoid them can
vary significantly. This is the reason why a differentiation is made between
different types of safety - e.g. by specifying the cause of possible hazards.
"Functional safety" is involved when the safety depends on the correct function.
The requirements to achieve functional safety are based on the following basic
goals:
• Avoiding systematic errors
• Controlling systematic errors
• Controlling random errors or failures

CE marking Machines that, with regard to the machinery directive, are usable, ready to use
and operational, receive the CE marking as part of the conformance declaration.
Safety components receive only the EC Declaration of Conformity, but no CE
marking!

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Training Document 14 - 4 Drive based safety integrated
Article 137 The EC Directives for occupational safety and for machine use mainly address
the users of machines. The level of protection defined in the minimum
requirements can be increased through national regulations.
The "Safety and health of workers at work" Council Directive (89/391/EEC)
defines minimum requirements for safety in the workplace
In Germany, the requirements are summarized in the German Health and
Safety at Work Regulations (BetrSichV).
You will find more information (in German) on the Internet pages of the Federal
Institute for Occupational Safety and Health (BAuA)
(http://www.baua.de/baua/index.htm)

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Training Document 14 - 5 Drive based safety integrated
Objective At no time may the use of a machine result in danger to people, machines and
the environment.
The machine directive helps the machine manufacturer to detect any dangers
caused by a machine and adopt the appropriate preventative measures before
the machine is marketed. This process is also called hazard assessment that
with a risk evaluation results in the necessary protective measures.
The EN ISO 12100 is a standard that the machine manufacturer can apply to
establish and define safety measures.

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Training Document 14 - 6 Drive based safety integrated
Harmonized standards The standards that have proliferated in various countries in the past are being
harmonized by the two standards organizations CEN (Comité Européen de
Normalisation) and CENELEC (Comité Européen de Normalisation
Électrotechnique), mandated by the EU Commission to precisely specify the
requirements of the EU directives for specific products.
These EN standards are published in the Official Journal of the European
Communities and must be included in domestic standards without any revisions.

EN 954-1 Obsolete standard - replaced by ISO 13849. It provides only the categories and
does not contain any numeric evaluation and so there is no possibility to check
a result using a calculation.

ISO 13849-1 This also includes programmable controllers (defined architectures); supplies
PLs; during a transition period until 10/2009, both 13849-1 and 954-1 may be
used; relevant for machine constructors.

IEC 61508 Is designated as the basic standard for the functional safety; it is not
harmonized under MD -> it does not include any presumption of conformity;
despite this, it can be used for satisfying European directives when no
harmonized standard is available or when it is referenced in a harmonized
standard; characterizes the "state-of-the-art"; supplies SILs; relevant for
manufacturers of safety devices.

IEC 62061 Harmonized under MD; it is a sector-specific (machine) standard below

IEC 61508; includes controllers; supplies SILs as result; relevant for machine
builders.

IEC 61800-5-2 Standard for electrical drives; it specifies, for example, the behavior of the
machine for STO, SS1, SS2, etc.

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Training Document 14 - 7 Drive based safety integrated
Machinery directive The machinery directive demands from EC member states that only those
machine and safety components that meet the safety and health requirements
listed in Appendix 1 may be brought to market and operated.
Countries are not allowed to prohibit, limit or hinder the marketing and operation
when the manufacturer declares conformity with the basic requirements of the
machinery directive.

Objective At no time must the use of a machine result in danger to people, machines and
the environment.
The machinery directive helps the machine manufacturer to detect any dangers
caused by a machine and adopt the appropriate preventative measures before
the machine is marketed. This process is also called "hazard assessment" that
with a risk assessment results in the necessary protective measures.
The risk assessment is not a process performed after a machine has been built,
by testing the risks of the machine that has already been constructed. Dangers
that are not detected until at this stage can hardly be removed (or at least
minimized), and if at all only at high cost.
The risk assessment considers the complete lifecycle of the machine (even
during the design planning stage); in particular:
• The assembly
• The setup mode
• The normal operation
• The maintenance and servicing
• The decommissioning, and finally
• The disassembly

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Training Document 14 - 8 Drive based safety integrated
 The principle of risk minimization clarifies the responsibilities. In this case the
machine manufacturer is the responsible.
Modified design: Example: Steam sterilization instead of sodium hydroxide rinsing

Measures A variety of measures are possible to minimize the risk. For example:
• Rounded edges
• Training of the employees
• Installation of fixed covers
• Information for operators (warning signs, etc.)
• Compact operating instructions

Safety engineering The following devices or functions may be implemented as technical measures:
• Contactless protective equipment (safety light arrays, safety light barriers,
etc.)
• Disconnecting protective devices (protective doors, protective covers, etc.),
the opening of which is monitored/prevented using safety technology
• EMERGENCY-STOP switching devices
• Two-hand control units
• Drive-integrated safety functions, e.g. SINAMICS drive-based Safety
Integrated

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Training Document 14 - 9 Drive based safety integrated
EN ISO 12100, "The purpose of this section is to describe the basic dangers and thereby to
support the designer in identifying ... hazards."
Definitions
Danger Origin of the damaging impact.
Depending on the current effect, the danger may be active or dormant

Danger area Area where a damaging impact unfurls

´
Danger situation Situation where an individual is close to a danger; three types:
• Person near a dormant danger
• Person in the vicinity of a dormant danger
• Person near an active danger

Hazard Dangerous situation where an individual is in the area of a dormant danger.

Event Takes places where an individual is exposed to a damaging impact. Risk

assessment attempts to record events and derive measures that prevent
damage or reduce a risk to a tolerable minimum.

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Training Document 14 - 10 Drive based safety integrated
Severity Severity of the injury or damage
• Type of the "legal entity" to be protected (persons, objects, environment)
• Type of the injury (for persons) (minor, severe, lethal)
• Injury scope (one/several persons)

Frequency Frequency and duration of the exposure to danger

• Necessity of access (operation, maintenance, repairs, ...)
• Duration of exposure in the danger area (familiarity with the danger)
• Frequency of access, number of persons
• Statistics, accident history, risk comparisons

Avoidance Possibilities of avoidance

• Construction measures
• Supervision of the operation (e.g. also via video surveillance)
• Need for specifically trained personnel

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Training Document 14 - 11 Drive based safety integrated
Static variables Calculated and achieved safety levels that represent the "dangerous failures per
period" are always static variables. To put it another way: If a safety level SIL 1
reaches a value 2.7x10-5 for example, this means that 1.1826 dangerous
failures could theoretically occur within 5 years. This does not mean that such a
failure will necessarily occur just after 5 years, nor that 4 years will pass without
such a failure.
If a fault does occur, this does not means that the next 4 years will go by without
anything happening again; similarly, as may be (quite probably) that nothing
goes wrong over the next 12 years.

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Training Document 14 - 12 Drive based safety integrated
 Certified safety devices facilitate acceptance testing.
Siemens drives are certified; e.g. G120 (SIL2), S120 (SIL2, PL d)
Other components for recording and processing (logic) also have certificates.
Certified components do not ensure that the required PL or SIL will actually be
achieved. The components for the subsystems can do this when they are
integrated accordingly. This is not ensured in conjunction with DETECTING-
EVALUATING-REACTING, however. This means:
• Sensor SIL3
• Logic SIL3
• Actuator SIL3 does not mean that the safety function automatically also
fulfills SIL3.

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Training Document 14 - 13 Drive based safety integrated
Detecting Can be separated into the subgroups optical sensors (light barriers, light
curtains, laser scanners, etc.) and switching technology (emergency-stop
button, position switch, etc.).

Evaluating This covers safety relays (3TK28) and controllers with the associated peripheral
devices (DIs, DOs and bus systems); a logical interconnection between
"detecting" and "reacting" is made here.

Reacting The actuators perform the reactions; in the most simple case, these are lamps
and contactors; complex devices such as frequency converters (e.g. S120) may
also be used.

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Training Document 14 - 14 Drive based safety integrated
 Standard and safety functions are implemented with separate controllers and
bus systems. Safety functions can be implemented with safety relays or a fail-
safe controller.
Whereas a standard PLC with distributed I/O (ET200S via PROFIBUS DP)
controls the standard functions of the system, a safety relay controls the
dangerous machine function.
This is the variant that has typically been used in the past because the drives as
actuators and controllers featured no safety technology. With this technology,
the drive is usually de-energized; sometimes it is first braked along a ramp.
The dangerous machine functions are switched via a positive-action contactor
that controls a safety-oriented safety relay. The safety relay receives the
associated control signals that are required for the correct shutdown by wiring
the appropriate signals from the system (such as those of the operator panel).

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Training Document 14 - 15 Drive based safety integrated
Safety Integrated Safety Integrated is the integral SIEMENS safety concept for the automation
and drive technology from SIEMENS. Proven technologies and systems from
the automation technology are used for the safety technology. Safety Integrated
contains the complete safety chain from encoder and actuator through to the
controller, including the safety-oriented communication using standard
fieldbuses. Drives and controllers also perform safety tasks in addition to their
function tasks. Integrated safety technology promises not only reliable safety
but, in particular, increased flexibility and improved productivity.
Standard and safety-relevant stations are coupled using a shared bus system.
Because bus-wide fail-safe communication is also possible, the bus can be
PROFIBUS, PROFINET (not for SIMOTION D) or a combination of both.

Advantages The integration of the safety technology in standard automation systems

provides the following important advantages:
• More flexibility than electromechanical solutions
• Reduction in wiring
• The coexistence of a standard and a safety program means that only one
CPU is required
• Simple communication between the standard and the safety program
• Reduced engineering cost because standard engineering tools are used for
the configuration and programming

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Training Document 14 - 16 Drive based safety integrated
 Basic Functions available on all device versions; no additional HW required.
Extended Functions on Booksize and Blocksize; for Chassis / S120CM /
cabinet units with new hardware and software (since mid 2009), i.e. with power
units that have -3 as last digit in the MLFB, SBC with FW >4.3.xx, i.e. with
CU320-2xx.
These can then be equipped with a DAC-CIM with IPD, which also has the X46
connector for controlling an external "safe brake relay" (digital-analog-converter
control interface module with intelligent powerstack data module).

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Training Document 14 - 17 Drive based safety integrated
Basic Functions These safety functions are part of the standard scope of the drive.
• Safe Torque Off (STO): STO is a safety function that prevents the drive from
restarting unexpectedly, in accordance with EN 60204-1:2006
Section 5.4.
• Safe Stop 1 (SS1, time controlled): Safe Stop 1 is based on the "Safe Torque
Off" function. This means that a Category 1 stop in accordance
with EN 60204-1:2006 can be implemented.
• Safe Brake Control (SBC): The SBC function permits the safe control of a
holding brake. Blocksize Power Modules also require a Safe Brake Relay for
this function.

Note The safety functions listed here conform to:

• Safety Integrity Level (SIL) 2 according to DIN EN 61508
• Category 3 according to DIN EN ISO 13849-1
• Performance level (PL) d according to DIN EN ISO 13849-1
The safety functions correspond to the functions according to
DIN EN 61800-5-2.

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Training Document 14 - 18 Drive based safety integrated
Extended Functions These functions require an additional safety license: Extended Functions with
encoder require an encoder with safety capability:
• Safe Torque Off (STO): STO is a safety function that prevents the drive from
restarting unexpectedly, in accordance with EN 60204-1:2006
Section 5.4.
• Safe Stop 1 (SS1, time controlled): Safe Stop 1 is based on the "Safe Torque
Off" function. This means that a Category 1 stop in accordance
with EN 60204-1:2006 can be implemented.
• Safe Brake Control (SBC): The SBC function permits the safe control of a
holding brake. Blocksize Power Modules also require a Safe Brake Relay for
this function.
• Safely-Limited Speed (SLS): The "Safely-Limited Speed" (SLS) protects
against excessively high drive speeds.
• Safe Stop 2 (SS2): The SS2 function brakes the motor safely with a
subsequent transition to "Safe Operating Stop" (SOS).
• Safe Operating Stop (SOS): The SOS protects against unintentional
movements. The drive is in closed-loop control mode and is not
disconnected from the power supply.

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Training Document 14 - 19 Drive based safety integrated
 • Safe Speed Monitor (SSM): SSM supplies a safe output signal if the drive
undershoots a defined speed limitSafe Direction (SDI): SDI is used to safely
monitor the direction of motion
• Safe Limited Position (SLP): The SLP function prevents the motor shaft from
exceeding the specified position limit(s).
• Safe Position (SP): SLP monitors up to 2 position ranges that are mutually
independent.
• Safe Brake Test (SBT): SBT tests the required holding torque of a brake
(operational or holding brake).
• Safe gearbox stage switchover: safe gearbox stage switchover allows you
to switch between 8 gearbox ratios in operation.

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Training Document 14 - 20 Drive based safety integrated
 • A safe two-channel digital input is available for the Basic Functions.
• The first channel is a DI of the CU320
 X122.1 -.4 = DI0 – DI3; X132.1 - .4 = DI4 – DI7
• The second channel is located on the EP terminal of the Motor Module.
 X21.3 (EP+), X21.4 EP ground
• Both channels must be operated exclusively as equivalent.
• Double Motor Module:
Observe the assignment of the power connection to the EP terminal
 Power connection X1 corresponds to EP X21
 Power connection X2 corresponds to EP X22

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Training Document 14 - 21 Drive based safety integrated
 • AC drives are operated either with CU310 or with CUA31/32.
• Up to format F, the Power Module is connected via the
 CU310 (terminals X120.7/.8)
 CUA3x (terminals X210.3/.4)
• The signals are transferred to the Power Module via PM-IF interface.
• For larger formats (Chassis), the CU310 is connected to the Power Module
via Drive-CLiQ
 Wire the safety signal directly to the MoMo (terminal X9.7/8)
 The X41 interface is not accessible due to the mounting plate for the
CU310 and/or CUA3x.

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Training Document 14 - 22 Drive based safety integrated
Cabinet units
• With Option K82, the safety terminal is wired to the customer terminal strip
• Furthermore, a coupling relay is interconnected
(to trigger with 230V and/or connect several Motor Modules over a larger
distance)
Chassis
• In the case of the Chassis Module,the same signal is always connected to
terminals X41.1 (EP+) and X41.2 (ground).

Note The connection is located on the Control Interface Board (CIB) and/or the
Control Interface Module (CIM) at the rear end of the electronic module.

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Training Document 14 - 23 Drive based safety integrated
SITRAIN Page Course DR-S12-PM
Training Document 14 - 24 Drive based safety integrated
Description In conjunction with a machine function or in the event of a fault, the "Safe
Torque Off" (STO) function is used to safely disconnect the torque-producing
power supply to the motor.
After selecting the function, the drive unit is in a "safe state". A movement
caused by mechanical forces is not prevented but must be implemented with a
separate holding brake.
The switch-on inhibit prevents the drive unit from being restarted.
The two-channel pulse suppression function integrated in the Motor Modules /
Power Modules is a basis for this function. One channel switches the upper
jumper of the power transistors (IGBTs) and the other the lower jumper.
The figure shows only the control via the on-board terminals. Control via
PROFIsafe and TM54F is also possible.
When tripped, the motor coasts to a standstill, provided that it is not stopped by
the load or a brake.

Features This function is drive-based, i.e. a higher-level control is not required.

• The function is drive-specific, i.e. it is available for each drive and must be
individually commissioned.
• The function enable is made from the appropriate input screens in
STARTER.
• The first 8 terminals on the CU320 can be parameterized as required for the
"Safe Torque Off" function. Therefore up to 8 axes can be switched
independently or in common in the STO.
The second terminal is always connected to the Motor Module belonging
to the drive; for this reason, Double Motor Modules have two terminals
(EP = Enable Pulses).

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Training Document 14 - 25 Drive based safety integrated
Note Different implementation of Basic and Extended Functions
Function
• Subsequent state in both cases STO
• In both cases, either braking along the OFF3 ramp or without OFF3
• Different step enabling conditions compared to STO
• Brake ramp is not monitored for Basic Functions.
Brake ramp with OFF3
• Brake ramp (OFF3) and delay time must match
• i.e. it must be possible to brake the drive down to standstill within the delay
time
• Factors to consider:
 Mass inertia
 Control dynamics of all controllers
 Dead times such as bus cycles, etc.

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Training Document 14 - 26 Drive based safety integrated
Description In conjunction with a machine function or in the event of a fault, the "Safe
Torque Off" (STO) function is used to safely disconnect the torque-generating
power supply to the motor.
After selecting the function, the drive unit is in a "safe state". A movement
caused by mechanical forces is not prevented, but must be implemented via a
separate holding brake.
The switch-on inhibit prevents the drive unit from being restarted.
The two-channel pulse suppression function integrated in the Motor Modules /
Power Modules is the basis for this function. One channel switches the upper
jumper of the power transistors (IGBTs) and the other the lower jumper.
The figure shows only the control via the onboard terminals. Control via
PROFIsafe and TM54F is also possible.
When tripped, the motor coasts to a standstill, provided that it is not stopped by
the load or a brake.
Function
characteristics This function is drive-autonomous, i.e. a higher-level controller is not required.
• The function is drive-specific, i.e. it is available for each drive and must
be commissioned separately for each drive.
• The function enable is made via the appropriate input screens in
STARTER.
• The first terminal on the CU320/CX32 for the "Safe Torque Off" function
can be freely parameterized. This means the selected terminal can
be used for several drives.
• Because the second terminal is always connected to the Motor Module
that belongs to the drive, Double Motor Modules have two terminals
(EP = Enable Pulses).

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Training Document 14 - 27 Drive based safety integrated
Selection The Safety Integrated functions of the SINAMICS S120 can only be
commissioned "online". After establishing an online connection, proceed as
follows:

1. First open the associated parameterization screen for each drive object by
entering: SINAMICS_xxx -> Drive_xxx -> Functions -> Safety Integrated.

2. Click the mouse in the opened parameterization screen on the "Change

settings" button.
The commissioning mode of the Safety Integrated Functions is now active.
A change of the parameterization screen is now no longer possible until the
commissioning has been completed.
In addition, the alarm "1698: SI CU: Commissioning active" is output.

3. For commissioning the basic functions, select the "STO/SBC/SS1" entry in

the "Select/control" list box with a terminal.
The screen for setting the parameters of the basic safety functions opens.
Only the "Activate settings" button can be used to exit the screen and thus
the commissioning mode of the safety functions.

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Training Document 14 - 28 Drive based safety integrated
Two-channel control All the main hardware and software functions for Safety Integrated are
implemented in two independent monitoring channels (e.g. control, switch-off
signal paths, data management, data comparison).
This means the two control paths of a drive are implemented with the following
input channels:
• DI of the Control Unit. One of the DIs 0 … 7 of the CU320 or one of the
DI 0…3 of the CU310 can be selected in the screen.
• The Motor Module (EP = Enable Pulses) or Power Module with CUA3x or
CU310 that belongs to the drive.

Grouping To ensure that the function works for more than one drive concurrently, the
terminals must be grouped as follows:
• 1st channel (CU320/D4xx, etc.): By connecting the binector input to the
common input terminal on the drives in one group.
• 2nd channel (Motor Module / Power Module with CUA3x): By appropriately
wiring the terminals for the individual Motor Modules/Power Modules with
CUA31/CUA32 belonging to the group.

Delay time If a low-signal is detected in both channels, the drive will be braked in
accordance with the OFF3 ramp (p1135) and stopped safely (STO) after
expiration of the delay time Tdelay (p9652/p9852).
The delay time set must allow the drive to brake down to a standstill within this
time. The basic SI functions do not provide any further monitoring of the brake
ramp.

SBC A Safe Brake control (SBC) can also be enabled and an output to display the
STO state (informative) can be specified within the screen.

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Training Document 14 - 29 Drive based safety integrated
Extended settings A click on the block for the "Extended settings" opens the 2nd screen. The
discrepancy monitoring time for a data cross-check of the two input channels
and a delay time from STOP F to STOP A are configured in this screen. The
duration of the forced dormant error detection is also specified.
Simultaneity
monitoring The input of the simultaneity time (e.g. T = 500 ms) is used for the discrepancy
monitoring of both input channels. Within this time, the two channels may have
different signal levels without a discrepancy fault being initiated.
If, for example, a low signal is detected in only one of the two input channels,
an OFF3 braking will also be started. Unlike the Safe Torque Off (STO), after
expiration of the delay time Tdelay, the discrepancy fault (STOP F) now initiated
after expiration of the simultaneity time causes a transition to STOP A and thus
STO again after expiration of the STOP F -> STOP A delay time.
To allow the drive to be braked to a standstill also for single-channel selection,
the sum of the simultaneity time (p9650/ p9850) and the STOP F -> STOP A
transition time (p9658/p9858) must be dimensioned so that the drive can brake
safely to standstill for OFF3.
The following SI faults and alarms are issued for a discrepancy fault:
• 30611: SI MM (or CU) defect in a monitoring channel
• 30600: SI MM: STOP A initiated
• 1500: SI CU: STOP A initiated
These faults can be acknowledged only with "Power on" or after a successful
test of the switch-off signal paths (protective door open/closed).

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Training Document 14 - 30 Drive based safety integrated
Forced dormant
error detection To fulfill the requirements of EN 954-1/ ISO 13849-1 and IEC61508 with respect
to timely fault detection, the functions and switch-off signal paths must be tested
at least once within a defined period to ensure that they function properly. The
maximum permissible interval for forced dormant error detection with the Basic
and Extended safety functions is 9000 hours or once a year.
After expiration of the time, the alarm "1699: SI CU test of the switch-off signal
paths required" is issued.
For the Basic Functions, the concurrent switching of the switch-off signal paths
(protective door open/closed) must be made for this purpose.

Copy parameters After completion of the input in the parameter screens, the "Copy parameters"
function must be initiated. This function copies the entered parameters (CU
parameters) to the associated storage locations on the Motor Modules (two-
channel data storage).

Activate settings "Activate settings" activates the configured inputs and exits the SI
commissioning mode. Prior to the activation, you will be requested to enter the
password. The default SI password setting is 0.
You will also be requested to back up data from RAM to ROM. The axis-related
backup suffices to save the changed SI parameterization on the CF card. The
project can then be downloaded to the PG.
The F1650 (2003) and F30650 (2003) faults will be issued when the
commissioning mode is exited. These notify that at least one SI parameter has
changed and so an acceptance test is required. The faults can be
acknowledged normally.

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Training Document 14 - 31 Drive based safety integrated
Acceptance test The acceptance test is designed to ensure that the safety functions are correctly
parameterized. The measured values are used to check the plausibility of the
configured safety functions. The measured values determined are typical and
not worst-case values. They represent the behavior of the machine at the time
of measurement. These measurements cannot be used, for example, to derive
maximum ramp-down values.
Extended
safety functions The acceptance test for systems with Safety Integrated Extended Functions
(SI functions) is focused on validating the functionality of Safety Integrated
monitoring and stop functions implemented in the drive system. The test
objective is to verify proper implementation of the defined safety functions and
of test mechanisms (forced dormant error detection measures) and to examine
the response of individual monitoring functions to the explicit input of values
outside tolerance limits.

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Training Document 14 - 32 Drive based safety integrated
Authorized person An authorized person may therefore also be an employee from another
company appointed to carry out tests where the above conditions are met. In a
practical sense, this means that e.g. a SIEMENS service technician may by all
means be involved in carrying out the acceptance test for the OEM and also
sign the acceptance report.
However, a competent employee working for the machine manufacturer is
entitled at all times to confirm the validity of the acceptance report; this is
generally the company's safety officer.

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Training Document 14 - 33 Drive based safety integrated
Documentation Overall acceptance of a machine obviously also includes corresponding
documentation of the safety-related mechanical parts, controllers, structures,
process description, etc. Particularly strict regulations also apply to machines
and plants which fall within the scope of FDA conformity.

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Training Document 14 - 34 Drive based safety integrated
STARTER Parameter lists/value lists created in STARTER simplify the documenting of
changes to individual content in parameters which often have to be re-recorded
during the acceptance test.
Further appendices can be attached to the acceptance report from the operating
manual, machine specifications, etc. A corresponding table of contents must be
created with a statement on the number of pages.

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Training Document 14 - 35 Drive based safety integrated
STARTER The option for producing standard-compliant acceptance test documentation is
integrated directly into the commissioning tool.
The document is restricted to the recording of drive-relevant safety parameters;
an F-CPU contained in the project or other devices integrated into the structure
of the safety system cannot be recorded here.

Function test Part 1 The data for function test Part 1 can be completed online provided that they
cover the parameters of the drive unit. This saves a lot of time and avoids any
typing errors.
Completion of
the report The document produced contains all necessary fields down to the signature
screens. It is created as an .rtf document that can also be edited in Microsoft
Word, for example.

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Training Document 14 - 36 Drive based safety integrated
Example document For the acceptance test protocol is provided in the Safety Integrated Function
Manual for the relevant drive type.
The details it contains refer exclusively to the dbSI functions of the drives.
Further safety-relevant machine components and/or functions must also be
tested and/or documented. (e.g settings for HW safety relays, safety light array
evaluation devices, safety light barriers, EMERGENCY-STOP switching
devices, ASi Safety at work, safety functions and programs, fail-safe controllers,
etc.)

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Training Document 14 - 37 Drive based safety integrated
Note If in doubt, always document, test and describe each change. Verification must
be made for work on already tested, accepted machines and systems each time
the safety systems are accessed; this verification may take the form of a
separate protocol or an appendix to the existing protocol.
The countersignature may also be made in electronic form, e.g. with an entry in
the shifts log and later printout with a real signature – the manufacturers must
define an appropriate procedure here for their safety officers to regulate the
handling of safety passwords.

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Training Document 14 - 38 Drive based safety integrated
Prerequisites Status of the device:
• First commissioning completed

Safety information Please note that:

• The course instructions have been produced for:
 A course held by a course leader
 Activities carried out on special training equipment
• The training equipment is operated under laboratory conditions.
In case of doubt, always ask your course leader – particularly when handling
components that carry electrical current or which can move.
• When carrying out work on equipment, the safety information in the
associated product documentation must always be observed!
The Training Documents alone are not sufficient.

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Training Document 14 - 39 Drive based safety integrated
Description Using this exercise, the basic safety functions integrated in the SINAMICS S120
drive are introduced ("drive based Safety Integrated Basic Functions").
You will learn about the following safety functions:
• Safe Torque Off (STO)
• Safe Stop 1 (SS1)

Note You will get to know the extended safety functions (dbSI Extended Functions),
for instance Safe Stop 2 (SS2), Safely Limited Speed (SLS), Safe Operation
STOP (SOS) and Safe Position (SPO) as well as generating the acceptance
protocol within the scope of the advanced course "DR-SNS-SAF".

Preparation It is possible to use the "dbSI Basic Functions" with any project that you use in
the course, in the "Servo" or "Vector" operating mode.
Select one of your projects, and make sure that the following functions operate:
• DI0: On/off 1 for "Servo_02"  the drive is switched on and switched off
• One of the purely digital inputs of CU320-2 (DI 1 to DI 7) is available and is
"deenergized"
Parameterize 5 seconds for the OFF3 ramp (so that you can clearly observe it).

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Training Document 14 - 40 Drive based safety integrated
Parameterization Scroll within your drive object "Servo_02" to the "Safety Integrated" function:
>> Drives > Servo/Vector > Functions > Safety Integrated

1. Activate the menu for the safety functions using the "Change settings" button
and enter a password of “0“ (or if required, “1“).

2. Select the variant “STO/SBC/SS1 via terminal“ in the "Safety function

selection" (variants with “Motion Monitoring“ are only for dbSI Extended“).

3. Assign the free digital input to the "Control Unit (DI1)“ input, and enter 2 s as
the simultaneity monitoring under "Extended settings.

4. Use the "Activate settings" button to activate the settings; if necessary,

define the number "1" as password (PLEASE do not use any other number
as a password) and save the changed axis parameters.

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Training Document 14 - 41 Drive based safety integrated
Function test Presently, both channel 1 and channel 2 signal “Pulse disable active = blocked“:
Channel 1 is enabled by the DI of the CU320-2, which you defined.
Channel 2 is enabled via “Enable Pulses, EP“ (on the exercise equipment
"2-axis case" with the switch located above the line switch).

1. Activate the two switches for the safety channels with a simultaneity of 2 s:
 A pulse enable is produced in both channels

2. Switch on the drive

 The motor accelerates to the specified setpoint speed.

3. Open the two switches for the safety channels "within 2 s":
 The pulses are immediately canceled (disabled) in both channels

4. Switch off the drive, close both switches for the safety channels "within 2 s"
and switch on the drive
 The motor accelerates to the specified setpoint speed.

5. Open one of the two switches for the safety channels:

 The drive is switched off after 2 seconds with the fault messages "STOP
A triggered" and "Defect in monitoring channel....".

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Training Document 14 - 42 Drive based safety integrated
Task Use the "Change settings" button to obtain access to further parameterization of
the safety functions and enter a password of "1".
Assign 10 s as delay time for SS1 in each case.
Use the "Activate settings" button to activate the settings; if necessary, define
the number "1" as password (PLEASE do not use any other number as a
password) and save the changed axis parameters.

Function test Close the two switches for the safety channels "within 2 s" to obtain the pulse
enable for both channels.

1. Switch on the drive

 The motor accelerates to the specified setpoint speed.

2. Open the switches for the safety channels “within 2 s“

 The motor decelerates with OFF3 to standstill, after 10 s the pulses for
both channels are canceled (disabled)

3. Switch off the drive, close both switches for the safety channels "within 2 s"
and switch on the drive
 The motor accelerates to the specified setpoint speed.

4. Open one of the two switches for the safety channels:

 The drive is switched off after 2 seconds with the fault messages "STOP
A triggered" and "Defect in monitoring channel....".

Power On Reset Acknowledge the pending error messages.

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Training Document 14 - 43 Drive based safety integrated
Learning Targets .............................................................................................................................. 2
Connection of the components ......................................................................................................... 3
Forms of communication .................................................................................................................. 4
SINAMICS link ................................................................................................................................. 6
OA-Link ............................................................................................................................................ 7
Connection of HMI-Panels ................................................................................................................ 8
PROFIDRIVE ................................................................................................................................... 9
Telegram overview ........................................................................................................................... 11
Hardware configuration .................................................................................................................... 13
Telegram configuration in STARTER ................................................................................................ 15
Communication ................................................................................................................................ 16
Reference variable ........................................................................................................................... 18
Reference variables ......................................................................................................................... 19
Cyclic and acyclic communication .................................................................................................... 20
Access points ................................................................................................................................... 22
S7ONLINE access point ................................................................................................................... 23
Access point S7ONLINE .................................................................................................................. 24
DEVICE access point ....................................................................................................................... 26
Access point DEVICE ....................................................................................................................... 27
Exercise 1: Add to the project ........................................................................................................... 30
Exercise 2: Test the project .............................................................................................................. 35

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Training Document 15 - 1 Communication
SITRAIN Page Course DR-S12-PM
Training Document 15 - 2 Communication
Automation The automation systems require various hardware and software components for
the machine control.
• HMI (Human Machine Interface)
• Control
• I/O
• Drives

Communication The various components in the automation system communicate with each
other via networks that are set up as a PROFIBUS network or PROFINET
network, for example.
There are often several different networks in an automation system, which are
then interlinked via modules that have a routing function.

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Training Document 15 - 3 Communication
SITRAIN Page Course DR-S12-PM
Training Document 15 - 4 Communication
PROFIdrive With its version of the drive profile PROFIdrive published in September 2005,
the PROFIBUS User Organization (PNO) produced an extended standard that
is applicable both to PROFIBUS and PROFINET. The long-proven PROFIdrive
profile at PROFIBUS is now also available for PROFINET under the same user
interface. Separation of the application and communication gives both the
manufacturers of devices and users trouble-free access to PROFIdrive
applications on PROFIBUS or PROFINET and thus the freedom to select the
optimal communication system.
The PROFIdrive drive profile describes the drive interface from the viewpoint of
the control application and its mapping to the communication system. It uses six
application classes to cover scenarios ranging from simple frequency
converters to highly-dynamic servo drives. PROFIdrive has been tried and
tested as an application profile for drives that use the PROFIBUS interface for
many years now; as of Version 4.0, it is also available for drives with
PROFINET communication. This means that drives for PROFIBUS and
PROFINET can be implemented using the same profile.
Cyclic
communication In each bus cycle, data are exchanged between the Profibus master/PROFINET
controller and the Profibus slave/PROFINET device. This is done typically on
the basis of standard telegrams.
Acyclic
communication Only on request are data are exchanged between the Profibus master/
PROFINET controller and the Profibus slave/PROFINET device. This data
exchange typically requires several bus cycles until a job is fully processed.

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Training Document 15 - 5 Communication
SINAMICS Link SINAMICS Link enables data to be directly exchanged between several Control
UnitsCU320-2 DP or CUD, which for this purpose must be equipped with the
CBE20 supplementary module. Other nodes cannot be integrated into this
communication. Possible applications include e.g.:
• Torque distribution for n drives
• Setpoint cascading for n drives
• Load distribution of drives coupled through a material web
• Master/slave function for infeed units
• Links between SINAMICS DC-MASTER and SINAMICS S120

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Training Document 15 - 6 Communication
SITRAIN Page Course DR-S12-PM
Training Document 15 - 7 Communication
HMI-Panel You can use a SIMATIC HMI as a PROFIBUS master (master class 2) to
access SINAMICS directly. With respect to SIMATIC HMI, SINAMICS behaves
like a SIMATIC S7. For accessing drive parameters, the following simple rule
applies:
• Parameter number = data block number
• Parameter sub-index = bit 0 ... 9 of data block offset
• Drive object number = bit 10 ... 15 of data block offset

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Training Document 15 - 8 Communication
 Cyclic communication is used to exchange time-critical process data.
Telegrams and
process data When a telegram is selected the drive unit (Control Unit) process data that is
transferred is determined.
From the perspective of the drive unit, the received process data represents 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

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.
For example there the following standard can be selected:
1: speed setpoint 16 Bit
2: speed setpoint 32 Bit
3: speed setpoint 32 Bit with 1 encoder for positioning
4: speed setpoint 32 Bit with 2 encoders for positioning
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.

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Training Document 15 - 9 Communication
Description There are different application classes for PROFIdrive, depending on the scope
and type of the application processes. PROFIdrive features a total of six
application classes, four of which are discussed here.

Application class 1 In the most basic case, the drive is controlled via a speed setpoint by means of
PROFIBUS/PROFINET. In this case, speed control is fully handled in the drive
controller. Typical application examples include simple frequency converters for
controlling pumps and fans.

Application class 3 In addition to the drive control, the drive also includes a positioning control,
which means that it operates as a self-contained single-axis positioning drive
while the higher-level technological processes are performed on the controller.
Positioning requests are transmitted to the drive controller via
PROFIBUS/PROFINET and launched. Positioning drives have a very wide
range of applications, e.g. the screwing and unscrewing of caps in a bottle filling
plant or the positioning of cutters on a film cutting machine..

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Training Document 15 - 10 Communication
Interfacing When interfacing via PROFIdrive, standardized telegrams in accordance with
the PROFIdrive profile are used to transfer all information between the drive
system and the SIMATIC. The structure and type of the information being
exchanged uniquely defines the number of the telegram.

Standard telegram 1 Is designed for simple speed-controlled applications. The telegram has a control
and a status word via which the basic functionality regarding activation,
deactivation, pulse and controller enable is handled. A 16-bit data word is used
for transferring the speed setpoint. The actual speed value is also transferred
back from the drive in 16 bits.

Standard telegram 3 Is designed for positioning applications. It also has an encoder control word and
encoder status word, as well as a 4-word interface to a measuring system. This
encoder control word implements functions, such as homing and measuring
input.

Standard telegram 9 Is designed for controlling a positioning axis via MDI positioning.

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Training Document 15 - 11 Communication
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.
Examples for standard telegrams:
• 1 16-bit speed setpoint
• 3 speed setpoint, 32-bit with 1 position encoders
• 4 speed setpoint, 32-bit with 2 position encoders
• 5 speed setpoint, 32-bit with 1 position encoder and DSC
• 7 positioning, telegram 7 (basic positioner)
• 81 encoder telegram, 1 encoder channel
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.
Examples for SIEMENS-specific telegrams:
• 110 positioning, telegram 10 (basic positioner with MDI, override and Xist_A)
• 111 positioning, telegram 11 (basic positioner in MDI mode)
• 118 speed setpoint, 32-bit with 2 external position encoders, torque reduction
and DSC, as well as load, torque, power, and current actual values
• 370 infeed
• 390 Control Unit with digital inputs/outputs

Free telegrams The send and receive telegrams can be configured as required by using BICO
technology to interconnect the send and receive process data.

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Training Document 15 - 12 Communication
Open station To open "HW Config" from STARTER for a station that has already been
configured, simply double-click in the project navigator on the desired
SINAMICS device.
This step is required when additional HW components should be added
subsequently or when changes or checks should be made to previously
configured stations or HW components.
Hardware
configuration The hardware configuration is made with the "HW Config" editor. The hardware
in the project is simulated, e.g.:
• Type of the SINAMICS device
• Type of the I/O modules
In addition, set the parameters for the entire SIMATIC and SINAMICS project,
e.g.:
• Configuration of the SINAMICS devices
• Configuration of the PROFIBUS and assignment of the PROFIBUS
hardware
• Configuration of PROFINET and assignment of the PROFINET hardware

HW Config The "HW Config" editor is shown in the above figure: It consists of:
• A "Hardware Catalog" window
• A "two-part work window" that shows the rack or station frame with the CPU
inserted in slot 2, as well as detailed information on the selected objects.
Further objects can be added and edited from the hardware catalog.

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Training Document 15 - 13 Communication
General Data transfer between SIMATIC and SINAMICS for Filler_red drive is carried
out via the Profibus Standard Telegram 9.

I/O address Output address PAW 256 is used to transfer the process data (control word,
setpoint, etc.) to the drive and return the actual values, for example, via the
inputs.
The Standard Telegram 9 is output via output word PAW256 - PAW276
(10 words). The system function SFC 15 is required for transfer.

PROFIBUS master Is the CPU with address 2 in the example shown.

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Training Document 15 - 14 Communication
Telegram
configuration Besides the hardware configuration, the telegram configuration is also defined
in STARTER.
The following commands can be used to open an overview of the telegrams that
are assigned to drive objects:
>> Drive unit -> Communication > Telegram configuration

Compare telegram When the telegrams for the drive objects are defined in the STARTER, it is
necessary to enter the communication data in the hardware configuration also.
This can be done either manually or using the "Set up address" button. This
sets up the I/O ranges in the hardware configuration according to the telegram
settings in the STARTER.

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Training Document 15 - 15 Communication
Receive signals The signals received via Profibus or Profinet can be displayed word-by-word,
double-word-by-double-word or even bit-by-bit with Starter in online mode.
These signals are provided by appropriately assigned read parameters:
• Word-by-word: r2050[0], r2050[1], …
• Double-word-by-double-word: r2060[0], r2060[1], …
• Bit-by-bit: r2090.0, …, r2090.15, r2091.0, …,
r2091.15, …
In this way, these signal can also be linked on to other drive parameters of the
corresponding format.

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Training Document 15 - 16 Communication
transmit signals The signals sent via Profibus or Profinet can be displayed word-by-word,
double-word-by-double-word or even bit-by-bit with Starter in online mode.
These signals are provided by appropriately assigned write parameters:
• Word-by-word: p2051[0], p2051[1], …
• Double-word-by-double-word: p2061[0], p2061[1], …
• Bit-by-bit: p2080[0], …, p2080[15], p2081[0], …,
p2081[15], …

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Training Document 15 - 17 Communication
Reference variables Numerous variables, such as speed, are not specified as absolute values, but
as a percentage of a reference variable.
This means that the speed is configured and output as a percentage of the
reference speed.
You can specify the following variables:
• Reference speed / reference frequency
• Reference voltage
• Reference current
• Reference torque
• Reference power
• Reference angle
• Reference acceleration
The reference variables are defined during the commissioning phase but may
be adapted at any later time.

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Training Document 15 - 18 Communication
Conversion If the speed is specified via a higher-level PLC, for example, this value is
specified as a percentage of the reference speed.

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Training Document 15 - 19 Communication
Cyclic
communication Cyclic communication is typically performed on the basis of PROFIBUS
standard telegrams, whereby a defined number of words are transferred to the
slave/device depending on the length of the telegram and a defined number of
words are read from the slave/device in each bus cycle.
This cyclic exchange of data is also supported by system functions that enable
consistent sending and receiving of several words via the I/Os.
Acyclic
communication Only upon request, data are exchanged between the Profibus master and the
Profibus slave. This data exchange typically requires several bus cycles until a
job is fully processed.
This data exchange is supported by system function blocks that carry out
processing of the data request.

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Training Document 15 - 20 Communication
Acyclic services Besides the cyclic communication there is also an acyclic communication which
tranfers data only if it is necessary e.g. to read out alarms or transfer a new
taregt position.
To make it easier there is a toolbox with the FB283 to support the programming
of the acyclic communication.

FB283 The SINAMICS toolbox comprises a sample project 'Fb283_Bsp_V2_1.zip',

which includes an interface block that allows to conveniently connect the
SINAMICS converters to PROFIBUS / PROFINET.
This version supports the following converters:
SINAMICS G120
SINAMICS G120D
SINAMICS G130
SINAMICS G150
SINAMICS S110
SINAMICS S120

Tasks of the FB283 The function block FB283 allows to transfer all the necessary drive process
data. This block is especially suitable for actuating the EPOS functions of the
SINAMICS S110 and S120, but it can also be used as a mere speed drive.
Further, the FB283 provides the following functions:
The existing drive parameters can be read or overwritten. The fault buffer can
be read out. You can transfer up to 64 traversing blocks with one function
trigger. Max. 10 arbitrary parameters can be read / written with one job (e.g. to
adapt the product).

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Training Document 15 - 21 Communication
PG connection The PG/PC connection for the configuring, commissioning and the service can
be performed using interfaces on the SINAMICS.
The following interfaces are available:
• 1 PROFIBUS interface DP1 (for CU320-2 DP only)
• 2 PROFINET interfaces PN (for CU320-2 PN only)
• 1 Ethernet interface X127
• CBE20 option module for PROFINET with 4 RJ45 connections
• CBC10 option module for CAN bus
For configuring the interface, STARTER uses the STEP 7 tools HW Config and
NetPro.

S7ONLINE The selection S7ONLINE is the key to TIA integration. It enables communication
to be established via the system network specified in the project, e.g. via
PROFINET/PROFIBUS/MPI, with all directly connected devices, with connected
controllers and, with the use of the S7 routing, even to the subordinate drives
connected to these controllers. This assumes that the nodes support routing.

DEVICE The DEVICE selection provides the option of connecting STARTER (STARTER
V4.2 and higher) directly to a device either in parallel or alternatively to
S7ONLINE, e.g. via the Ethernet interface. In this way, you can communicate
quickly with the device without having to make changes to the project settings,
either via the system network or via a separate connection in order, for
example, to adapt the parameterization or read out the diagnostics information.

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Training Document 15 - 22 Communication
SIMATIC Manager If the drive is operated within an automation system using a SIMATIC, the
SIMATIC Manger is used as the central starting point for engineering and
service.
If the drive is integrated into the network via the HW Config, this drive is visible
as an object in the SIMATIC Manager.

STARTER Double-click on the drive to open the STARTER. Alternatively, the

"Commissioning" button of the STARTER can be used to open it.

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Training Document 15 - 23 Communication
NetPro The networks and network components of an automation system are shown in
NetPro.
Graphic connections are used to define which networks and which connections
are to communicate with each other.
In addition to the components like the CPU and the drives, the PCs/PGs are
also integrated.
This integration permits, in particular, the access to nodes that are not
connected to the same subnet but are only accessible using a gateway (router).
Access point
S7ONLINE The access point of the SIMATIC Manager is S7ONLINE. Configuration can
take place via the "Set PG/PC interface" menu if no connection is defined in
NetPro.
If a connection is defined as an S7ONLINE connection in NetPro, this
connection is highlighted in yellow. Modification via "Set PG/PC Interface…"
deletes this yellow connection and the user loses the routing information.

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Training Document 15 - 24 Communication
Properties The context menu of the drive unit can be used to access the "Properties" menu
item to hide the properties of the drive unit/access point.
The following information is displayed:
• Device family
• Device
• Device version
• Order number
• Version
and
• Access point in use
 S7ONLINE
 DEVICE (STARTER, SCOUT).

"Set S7ONLINE addresses" can be used to show which addresses the target
device must have for STARTER to go online.

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Training Document 15 - 25 Communication
SITRAIN Page Course DR-S12-PM
Training Document 15 - 26 Communication
Access point The access path to the device for the access point DEVICE is configured in the
properties dialog of the SINAMICS S120. Here, the interface and addresses to
be used to establish the connection are set under the "DEVICE addresses" tab.
When starting to establish the connection, the PG/PC attempts to contact the
connection partners using these addresses.
These addresses do not necessarily have to match the addresses configured in
HW Config. However, if the PG/PC is locally connected to the SINAMICS then
in order to successfully establish a connection, they have to match the actual
addresses of the target system.
In the properties dialog, yellow is used to display via which connection
(PROFIBUS, Ethernet) the connection should be established. For this display,
the settings of the access point DEVICE are evaluated in the dialog "Set PG/PC
interface".

PG interface The PG/PC interface to be used to establish the connection to the target device
is specified in the "Set PG/PC Interface" dialog. After selecting the DEVICE
access point, in this dialog, in the list box "Access point of the application" the
interface drivers to be used must be selected in the list box "Interface parameter
assignment used".
When accessing via PROFIBUS, this dialog is also used to set the
communication baud rate. When selecting Ethernet communication, i.e. driver:
"TCP/IP – Intel® 82…." the IP address of the PG/PC must be set in the
properties of the Windows control panel.

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Training Document 15 - 27 Communication
DEVICE address The DEVICE addresses are also displayed in the properties next to the
S7ONLINE address.
Use the "Set DEVICE addresses" menu to set which address STARTER uses to
set up an ONLINE access to the target device.
If a connection is to be set up to LAN port X127, for example, the matching
interface configuration for the DEVICE access point must be set via the
"Set PG/PC connection" menu.
Then, the IP address must be entered in the Properties screen.
Finally, "DEVICE" must be selected as the access point in the "Select target
device" menu.
It is now possible to establish a connection to the drive via the "Connect target
device" button.

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Training Document 15 - 28 Communication
Prerequisites Status of the device:
• First commissioning completed

Safety information Please note that:

• The course instructions have been produced for:
 A course held by a course leader
 Activities carried out on special training equipment
• The training equipment is operated under laboratory conditions.
In case of doubt, always ask your course leader – particularly when handling
components that carry electrical current or which can move.
• When carrying out work on equipment, the safety information in the
associated product documentation must always be observed!
The Training Documents alone are not sufficient.

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Training Document 15 - 29 Communication
Task This exercise will consolidate your knowledge of the communication between a
SINAMICS S120 and an S7-CPU.
Start this exercise with an S7 project to which you add an S120 drive unit. You
can then use a variable table to control the drive.

1. In the first step, the drive is to be traversed with a defined configuration.

Open the archived project "S120_Servo_1", load the data to the drive unit
and test the rotation of the motors.

2. Save the data to the ROM of the Control Unit. These data will be loaded from
the drive unit to the drive unit of the S7 project and modified during the
course of the exercise.

3. This exercise uses the S7-CPU integrated in the training equipment. This is
a CPU315-2 PN/DP that has a PROFIBUS and a PROFINET interface.
The PROFIBUS interface integrates the Control Unit of the drive. The CPU
communicates with the PG via the PROFINET interface.
Connect the Control Unit with the PROFIBUS cable.
Use the Ethernet cable to connect the CPU to the left LAN interface of
the PG.

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Training Document 15 - 30 Communication
 4. Open the SIMATIC Manager.

5. Open the "S120_servo_V46_start" project. This project already has a

hardware configuration, the OB1 and a variable table. The PG has been
integrated in NetPro.

6. Open the hardware configuration in the project.

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Training Document 15 - 31 Communication
 7. The CPU and the central modules are already integrated in the hardware
configuration.

8. A PROFIBUS network and an Ethernet network has also been created. Add
a CU320-2 DP from the catalog as slave with the following data: PROFIBUS
address 4, firmware 4.6. Complete the configuration of the telegrams by
clicking "OK".

9. Save and compile the hardware configuration and close the hardware
configuration.

10.Open the SIMATIC Manager. After successful compilation of the hardware

configuration, a SINAMICS slave has been integrated into the project.

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Training Document 15 - 32 Communication
 11. STARTER must be open in order to commission the drive object:

>> S120_CU320_2_DP > S120_CU320_2_DP > Commissioning

12. The STARTER project is opened.

13. Go online with STARTER and download the data from the CU 320-2 to the
PG, save them and go offline.

14. The communication between the drive object and the S7-CPU must now be
adapted. Open the communication screen.

15. This table shows the objects in the project. You can set which telegram an
object uses to communicate with the higher-level controller here. Select the
standard telegram 1 for both drive objects. The "Set up addresses" button
is used to transfer the telegram settings to the hardware configuration of
the S7 project.

16. Save the data in the project, go online and upload the data to the CU. Then
save the configuration in ROM.

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Training Document 15 - 33 Communication
 17. Open the hardware configuration.
Double-click on the drive icon to open the window for the DP slave
properties. The "Configuration" tab now shows the telegrams entered by
the STARTER. Each object has been assigned standard telegram 1.
Data exchange takes place via the I/O interface.
Drive 1: I/O address: P256 – P259
Drive 2: I/O address: P260 – P263
The data is grayed out to make clear that these data have been changed
by the STARTER. The "Activate" button can be used to change the
telegrams; they must then be transferred to the STARTER again.

18. Transfer the hardware configuration to the controller.

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Training Document 15 - 34 Communication
 An OB1 object that transfers the data for the first drive from the I/O address to
the MW and from the MW to the I/O address is stored in the S7 project.
• MW20: PEW 256 MW24: PAW 256
• MW22: PEW 258 MW26: PAW 258
The memory words are listed as symbolic names in the variable table.

Task Now test the communication.

- Open the "Control_S120" variable table
- Set the flag to move the drive.

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Training Document 15 - 35 Communication
Learning Targets .............................................................................................................................. 2
Line contactor control ....................................................................................................................... 3
Brake control .................................................................................................................................... 4
Flying restart .................................................................................................................................... 5
Vdc controller ................................................................................................................................... 6
Parallel connection of power units .................................................................................................... 9
Redundancy mode for power units ................................................................................................... 10
Booting with sub-topology ................................................................................................................ 11
Simulation mode .............................................................................................................................. 12
Synchronization and bypass ............................................................................................................. 13
Motor change over ........................................................................................................................... 14
Parking axis / parking encoder ......................................................................................................... 15
Vertical axis / travel to fixed stop / ................................................................................................... 16
Technology PID controller ................................................................................................................ 17
Drive Control Chart .......................................................................................................................... 18

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Training Document 16 - 1 Further drive function
SITRAIN Page Course DR-S12-PM
Training Document 16 - 2 Further drive function
Description This function can be used to control an external line contactor. Opening and
closing the line contactor is monitored by evaluating the feedback contact in the
line contactor. The line contactor is used for the electrical isolation of the DC link
for the energy supply network.

The line contactor can be controlled using the following drive objects:
• Via bit r0863.1 of drive object INFEED
• Via bit r0863.1 of drive object SERVO/VECTOR

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Training Document 16 - 3 Further drive function
 The "extended brake control" function has the following features:
• Forced brake release (p0855, p1215)
• Application of brake for a 1 signal "unconditionally close holding brake"
(p0858)
• Binector inputs for releasing/applying the brake (p1218, p1219)
• Connector input for threshold value for releasing/applying the brake (p1220)
• OR/AND block, each with two inputs (p1279, r1229.10, p1229.11)
• Holding and operational brakes can be activated.
• Function for monitoring brake feedback signals (r1229.4, r1229.5)
• Configurable responses (A7931, A7932)
• Application of brake after the "enable speed controller" signal has been
canceled (p0856)

Examples Start-up with brake applied

When the motor is switched on, the setpoint is enabled immediately (providing
the required enabling signals have been issued) even if the brake has not yet
been released.
Emergency brake
During emergency braking, electrical and mechanical braking should be
performed simultaneously. This can be achieved when OFF3 is used as a signal
to trigger emergency braking.
Operating brake for crane drives
For hoisting gear with a manual control, it is important that the drive immediately
responds when the control lever is moved (master switch). To ensure this, the
drive is switched on using the On command (p0840) (pulses are enabled). The
speed setpoint (p1142) and speed controller (p0856) are inhibited. The motor is
magnetized. The magnetization time required for three-phase motors (1-
2 seconds), therefore, no longer applies.

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Training Document 16 - 4 Further drive function
Description After power on, the "flying restart" function automatically connects a Motor
Module to a motor which may already be turning.
The "flying restart" function should be activated via p1200 for any trailing load.
This can prevent abrupt loads on the entire mechanical system.
Prior to searching, it is necessary to wait for a demagnetizing time for an
asynchronous motor. An internal demagnetization time is calculated. A time can
also be entered in p0347. The longer of the two times applies.
In operation without an encoder, a search is carried out for the current speed
initially. The search starts at the maximum speed plus 25%. A Voltage Sensing
Module (VSM) is required for permanent-magnet synchronous motors.
When operated with encoder (actual speed value is recorded), the search
phase is omitted.
For an asynchronous motor, magnetization (p0346) is carried out first
immediately after the speed has been determined.
Then the current speed setpoint in the ramp-function generator is set to the
current actual speed value.
Ramp-up to the final speed setpoint is carried out from this value.

Example After a power failure, a fan drive can be quickly reconnected to the running fan
motor by means of the "flying restart" function.

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Training Document 16 - 5 Further drive function
Description The Vdc_max controller can be used to react to overvoltage of the DC link line-
up. In the line-up, one or more drives can be used to relieve the DC link. This
can prevent a fault from occurring due to the DC link overvoltage and ensures
that the drives are always ready to use.

This function is activated with the configuration parameter (p1240). A reaction

can be activated if an overvoltage is present. The torque limits of the motors at
which the Vdc controller is active can be affected if discrepancies in the DC link
voltage are significant enough. The braking phases are longer for these motors.

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Training Document 16 - 6 Further drive function
Description The Vdc_min controller, also referred to as kinetic buffering, can be used to
react to undervoltage of the DC link line-up. In the line-up, one or more drives
can be used to relieve the DC link. This can prevent a fault from occurring due
to the DC link undervoltage and ensures that the drives are still ready to use.

This function is activated with the configuration parameter (p1240). A reaction

can be activated if an undervoltage is present. The torque limits of the motors at
which the Vdc controller is active can be affected if discrepancies in the DC link
voltage are significant enough. These motors can no longer maintain their set
speed.

The Vdc_min controller is an automatic P controller that influences the torque

limits. It only intervenes when the DC link voltage approaches the "lower
threshold" (p1248) and the corresponding controller is activated via the
configuration parameter (p1240).

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Training Document 16 - 7 Further drive function
Benefits It can make sense to connect power units (Line Modules and Motor Modules) in
parallel for a variety of reasons:
• To boost the converter output if it is not technically or economically feasible
to achieve the required output power by any other means.
• To increase availability in cases where it is necessary to maintain
emergency operation when a frequency converter develops a fault – and
where a reduced power can be tolerated.
Features The main features of parallel connection are:
• Parallel connection of up to 4 Motor Modules on one motor
• Parallel connection of up to 4 power units on the infeed side (closed/open
loop).
• A Control Unit which controls and monitors parallel connections of power
units at the infeed and motor ends. In this case, the Control Unit is not
capable of controlling any motor or vector axes in addition to the parallel
connections.
• Redundant operation:
Two Control Units which control and monitor parallel connections of power
units at the infeed and motor ends. In this case, the Control Units are not
capable of controlling any motor or vector axes in addition to the parallel
connections.
• The power units connected in parallel must be connected to the same
Control Unit.
• With a CU320-2 DP, a maximum of one parallel connection on the line side
and one parallel connection on the infeed side can be implemented.
• Components at the line and motor ends for decoupling the parallel-
connected power units and for ensuring symmetrical current distribution.
• Simple commissioning, because no special parameterization is necessary.
Individual power units can be parameterized and diagnosed
(troubleshooting) with p7000 ff.

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Training Document 16 - 8 Further drive function
Description The redundancy mode can be used to continue operation despite the failure of a
power unit connected in parallel.

In order that the failed power unit can be replaced, DRIVE-CLiQ cables must be
connected in a star-type configuration – it may be necessary to use a DRIVE-
CLiQ HUB Module (DMC20 or DME20). The failed power unit must be
deactivated via p0125 or via the binector input p0895, before it is removed.
When a replacement power unit has been installed it must be activated
accordingly.
Features
• Redundancy for up to 4 chassis power units
• Power unit can be deactivated via parameter (p0125)
• Power unit can be deactivated via binector input (p0895)
Preconditions
• Parallel connection only works with equivalent (same order number)
chassis power units.
• Maximum number of parallel power units is 4
• Parallel connection of power units with suitable power reserves
• DRIVE-CLiQ star topology (possibly a DMC20 or a DME20, refer to the
Equipment Manual)
• Motor with one single-winding system (p7003 = 0)
• No STO (Safe Torque off)

Note Despite this redundancy circuit, the entire plant may shut down when defects
develop in a power unit (feedback effects due to absence of electrical isolation).

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Training Document 16 - 9 Further drive function
Removal With power switched off, remove "Drive 1" and change the DRIVE-CLiQ
connection.
After Power ON "Drive 1" is marked as "not operational".
. Messages: "Components missing" and "BiCo connections to inactive objects"
Save specified BiCo connections with p9495=1
Deactivate drive object "Drive 1" with p0105=0/save RAM  ROM

Installation With power switched off, install "Drive 1" and change the DRIVE-CLiQ
connection.
After Power ON the new serial number from "Drive 1" is transferred to the set
topology (with p9909=1).
Messages: "Object inactive and operational" and "Disconnected BiCo
connections present"
Activate drive object "Drive 1" with p0105=1
Set up BiCo connections again with p9496=1/
save RAMROM

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Training Document 16 - 10 Further drive function
Description Simulation mode is predominantly used to simulate the drive without a motor
being connected and without a DC link voltage. In this case, it should be noted
that the simulation mode can only be activated under an actual DC link voltage
of 40 V. If the voltage is higher, simulation mode is reset and fault message
F07826 is output.
Simulation mode enables you to test communication with a higher-level
automation system. If the drive is also to return actual values, note that it must
be switched over to encoderless operation during simulation mode. This means
that large parts of the SINAMICS software (e.g. setpoint channel, sequence
control, communication, technology function, etc.) can be tested in advance
without requiring a motor.
For units with outputs of > 75 W it is recommended to test the activation of the
power semiconductors after repairs. To do so, a DC voltage < 40 V is applied to
the DC link, and the possible pulse patterns must be tested by the control
software.
The software must allow enabling of the pulses and the output of various
frequencies. This is realized with U/f control or encoderless closed-loop speed
control.
The simulation mode is selected with the parameter p1272.

Note Simulation mode cannot be activated without a power unit. A power unit must
be connected via DRIVE-CLiQ.

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Training Document 16 - 11 Further drive function
Description With the "synchronization" function, the converter phase angle can be
synchronized with the line phase angle in order, for example, to switch over
(bypass) the motor directly to the mains supply afterwards. A further application
is the temporary operation of the motor on the line supply to perform
maintenance work at the converter without bringing the system down.
Parameter p3800 activates synchronization and selects actual voltage sensing
internally or externally.
In the case of internal actual value sensing (p3800 = 1), the voltage setpoints of
the electrical motor model are used for synchronization.
In the case of external actual value sensing (p3800 = 0), voltage sensing is
carried out via a VSM that is connected at the line phases.
These voltage values must be transferred to the synchronization via connectors
r3661 and r3662.
Features
• For asynchronous motors without sensor in “Vector” mode
• Line supply sensing using the Voltage Sensing Module (VSM10) connected
to drive object "infeed" or "vector" (p3801)
• Connector inputs for the actual voltage sensing of the motor via VSM10
(p3661, r3662)
• Setting of a phase difference (p3809)
• Can be activated by parameter (p3802)
Preconditions
• Drive object, vector/infeed with connected VSM10
• Asynchronous motor without sensor
• Vector control

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Training Document 16 - 12 Further drive function
Motor changeover The motor changeover is used in the following cases, for example:
• Changing over between different motors and encoders
• Switching over different windings in a motor (e.g. star-delta changeover)
• Motor data adaptation
If several motors are operated alternately on one Motor Module,
a corresponding number of drive data sets must be created.

Sequence Trigger pulse blocking by request for a new data set (p0820, 0821).
Internal deselection of the current data set deactivates motor contactor K4
(r0830).
On receipt of the feedback information “Contactor open“ and activation of the
requested data set, K1 is energized (r0830).
After receipt of feedback information “Contactor K1 closed“, pulse enable is
performed.

Note Using "Vector" mode:

To change to a rotating motor, the "flying restart" function must be activated
(p1200).

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Training Document 16 - 13 Further drive function
Parking axis Monitoring of all encoders and Motor Modules assigned to the "Motor control"
application of a drive is suppressed. All encoders that are assigned to the
"Motor control" application of a drive are prepared for the "encoder removed"
state.
The Motor Module that is assigned to the application "Motor control" of a drive is
prepared for the "Motor Module removed" state. When parking an axis, the
power unit and all encoders that are assigned to the "motor control" are
deactivated.

Parking encoder Monitoring of a certain encoder is suppressed. The encoder is prepared for the
"encoder removed" state.
When parking an encoder, the encoder is deactivated.

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Training Document 16 - 14 Further drive function
Vertical axis With a vertical axis without mechanical weight compensation, electronic weight
compensation can be set by offsetting the torque limits (p1532). The torque
limits specified in p1520 and p1521 are shifted by this offset value. The offset
value can be read in r0031 and transferred in p1532.
To reduce compensation once the brake has been released, the torque offset
can be interconnected as a supplementary torque setpoint (p1513). In this way,
the holding torque is set as soon as the brake has been released.
Travel to
fixed stop The "travel to fixed stop" function can be used, for example, to traverse sleeves
to a fixed stop against the workpiece with a predefined torque. In this way, the
workpiece can be securely clamped. The clamping torque can be parameterized
in the traversing task (p2622). A settable monitoring window for fixed stop
prevents the drive travelling beyond the window if the fixed stop breaks.
As soon as the axis pushes against the mechanical fixed stop, the control
increases the torque in the drive to continue moving the axis. The torque
increases up to the value specified in the task and then remains constant.

Friction characteristic The friction characteristic curve is used to compensate the friction torque for the
motor and the driven machine. A friction characteristic allows the speed
controller to be precontrolled and improves the control response.
10 interpolation points are used for the friction characteristic. The coordinates of
an interpolation point are described by a speed and a torque parameter.
An automatic function supports recording of the friction characteristic (friction
characteristic record). A connector output can be interconnected as friction
torque. The friction characteristic can be activated and deactivated.

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Training Document 16 - 15 Further drive function
Features Simple control functions can be implemented with the technology controller,
e.g.:
• Liquid level control
• Temperature control
• Dancer position control
• Pressure control
• Flow control
• Simple control without higher-level control
• Tension control

Characteristics The technology controller features:

• Two scalable setpoints
• Scalable output signal
• Separate fixed values
• Separate motorized potentiometer
• The output limits can be activated and deactivated via the ramp-function
generator.
• The D component can be switched to the system deviation or actual value
channel.
• The motorized potentiometer of the technology controller is only active when
the drive pulses are enabled.

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Training Document 16 - 16 Further drive function
SITRAIN Page Course DR-S12-PM
Training Document 16 - 17 Further drive function
 • SINAMICS S120, S150, SM150, G130, G150, GM150 and GL150
from firmware version V2.5 + SP1
• SINAMICS DCM from firmware version 1.1
• SIMOTION P, C, and D, Version 4.1 and higher
• SINAMICS integrated in SIMOTION D firmware version V2.5 + SP1 and
higher

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Training Document 16 - 18 Further drive function
DCC chart DCC charts are assigned to the respective drive object.
DCC charts can be created both directly under the SINAMICS CU320 or under
the respective motor object.

DCB library Drive Control Block library

For working with the pre-prepared blocks, the respective library must be
imported. When so doing, select the language for the help texts.
Once this library has been imported for a chart for this drive unit, it is available
for all other DCC charts within that drive unit.
User-specific
libraries For Starter V4.2 and DCC/CFC V7.1 and higher, it is possible to create and
import user-specific block libraries.

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Training Document 16 - 19 Further drive function
Libraries After the import, prepared blocks with the following functions are available in the
block catalog:
• Arithmetic blocks
• Closed-loop control blocks
• Conversion blocks
• Logic blocks
• System blocks
• Technology blocks

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Training Document 16 - 20 Further drive function
SITRAIN Page Course DR-S12-PM
Training Document 16 - 21 Further drive function
DCC chart A DCC chart can be created in STARTER for each drive object.
A DCC chart consists of max. 26 chart partitions (A, B, …, Z), which in turn can
each contain 6 chart pages (1, 2, …, 6).

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Training Document 16 - 22 Further drive function
Interconnections Creating a link between 2 blocks:

1. Select source of the interconnection

2. Select target of the interconnection

The interconnection is implemented.

Interconnections that span pages are implemented in the same manner.
A corresponding entry is made automatically in the sheet bar.
Double-click this entry to open the flashing interconnection to another sheet.
In this way, it is possible to jump quickly from the source to the target of an
interconnection as well as from the target to the source.

Note When an interconnection is made, DCC checks to what extent the data types of
the source and the target correspond. If they match, the interconnection is
created automatically. If the data types differ, no interconnection is created.
Instead, the following message is displayed:
Conversion blocks can then be used to match up the data types.

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Training Document 16 - 23 Further drive function
Publishing Each drive parameter interconnected to a block must be published before it is
compiled. The following syntax must be adhered to in this context:
• Connection parameter: @*Parameter no. Parameter name
• Value parameter: @Parameter no. parameter name

Parameter no. Each parameter published must be assigned its own parameter no.

Parameter name Each parameter published should be assigned its own parameter name.

Note After successful compilation, these parameters are incorporated in the expert
list of the assigned drive object.

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Training Document 16 - 24 Further drive function
 You could change the execution sequence as follow:

1. Open runtime editor

2. Select block

3. Move the block to the desired execution group and position using
drag-and-drop

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Training Document 16 - 25 Further drive function
 1. Select online mode.

2. Mark the blocks.

3. Select object properties and register I/Os for testing.

4. Register I/O for testing and select „watched“.

5. Set "Watch On" (using either 5a or 5b).

6. The registered block connections are shown with the current online data.

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Training Document 16 - 26 Further drive function
Learning Targets .............................................................................................................................. 2
Course DVD ..................................................................................................................................... 3
SITRAIN ........................................................................................................................................... 8
Service & Support ............................................................................................................................ 13
Technical documentation ................................................................................................................. 18

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Training Document 17 - 1 Support and training
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Training Document 17 - 2 Support and training
 The course DVD provides you with standard documentation for the courses on
SINAMICS low-voltage drives
The DVD contains the documentation for:
• Operation
• Programming
• Configuring
• Commissioning
• Functions

Note Acrobat® Reader must be installed before you can use the DVD.

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Training Document 17 - 3 Support and training
Starting the DVD To start the DVD, double-click in the Explorer on the "start.pdf" file or use the
File  Open menu in Acrobat® Reader to select the " start.pdf" file.

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Training Document 17 - 4 Support and training
DVD home page When you open the file "Start.PDF", the DVD's home page will be displayed
first.
You can click to select the documents of your choice in German or English on
this page.

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Training Document 17 - 5 Support and training
 The bookmark function of Acrobat® Reader is available for navigation through
the documentation.

Contents You can return to the first page of the document from any page in the document
by clicking the "Contents" button.

Return You can use the "Return to home page" button to return directly to the home
page of the DVD to select a different document.

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Training Document 17 - 6 Support and training
Find The files on the DVD are automatically linked to a search index when opened.
This facilitates a search over all files on the DVD using a search term entered.
All documents where the search term has been found are listed in the results
list. Click on the corresponding document to open it.

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Training Document 17 - 7 Support and training
 The full range of courses offered can be accessed using the following link:
www.siemens.com/sitrain or
www.siemens.com/sitrain

Course search The search function allows you to set various search filters such as keyword,
target group, etc. to find the desired course. The filters can also be combined.

Top links Top links provide direct access to a variety of courses, for example
SIMATIC S7, SINUMERIK solution line, etc.

Training news Here you will find the latest courses offered and SITRAIN activities at a glance.

Course catalog The course catalog enables you to find the desired course using training
methods or via the organizational structure of the Siemens Mall.

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Training Document 17 - 8 Support and training
 Example: SINAMICS S120 Safety Integrated

Description This course teaches you how to handle drive-integrated safety functions. You
will know how to apply the different functions and how you can parameterize
them. You will therefore be able to utilize the benefits of Safety Integrated
compared to conventional safety technology (e.g. reduced cabling or faster
standard commissioning).

Requirements Knowledge of SINAMICS S120 corresponding to course DR-SNS-SI.

Knowledge of SIMATIC S7 is advantageous for the topic PROFIsafe.

Target group Project managers, project employees,

Programmers
Commissioning personnel, configuring engineers

Contents Fundamentals, standards and regulations of machine safety

Procedure of risk assessment
Performance Level (PL) and Safety Integrity Level (SIL)
Safety Evaluation Tool (SET) for the determination of PL and SIL
SINAMICS S120 Safety Integrated Basic and Extended Functions
Control of the drive-integrated safety functions via
- Terminal Module TM54F and DRIVE-CLiQ
- SIMATIC F-CPU and PROFIsafe
Influence of the settings of the closed-loop controller and the kinetic energy of
an axis on the safety functions
Practical exercises on training equipment with SINAMICS S120, TM45F and
SIMATIC F-CPU

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Training Document 17 - 9 Support and training
 Example: SINAMICS G120 Service and Commissioning

Description Information required for engineering/configuring and the first commissioning of

the SINAMICS G120 drive system is provided in this course.
An important component of this course are practical exercises carried out on a
SINAMICS G120 training case.
At the end of this course, you are able to reliably handle the STARTER
commissioning tool. This means you are able to effectively use various inverter
functions, optimize closed-loop controls and achieve the best possible success
when using the SINAMICS G120 system.

Requirements Basic knowledge of electrical engineering

Target group Commissioning personnel, configuring engineers

Service personnel
Maintenance personnel

Contents Design of the SINAMICS G120 drive system

Commissioning and parameterization with the STARTER commissioning tool
Inverter functions (flying restart, braking, closed-loop control)
Data management
Flexible signal interconnection with BICO technology
Safety Integrated functions
Diagnostics and troubleshooting
Practical exercises using the training case

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Training Document 17 - 10 Support and training
 Example: SINAMICS G150 Service and Commissioning

Description This training course covers the technical knowledge for commissioning and
servicing SINAMICS chassis and cabinet units G130, G150 and S150.
Practical exercises for replacing spare parts and rectifying faults is a major part
of this course.
Once the course has been completed, you will be able to commission and
optimize drives, replace spare parts and carry out drive diagnosis using the
AOP30 or the STARTER tool.

Requirements Basic knowledge of electrical engineering

Target group Commissioning personnel, configuring engineers

Service personnel
Maintenance personnel

Content Design of the drive system and overview of documentation and service
Commissioning, servicing and diagnostics using the AOP30 operator panel and
the STARTER tool
Hardware functions, circuit diagrams and function diagrams
Software functions and controller optimization
Installation, electrical connection, EMC
Replacement of components in SINAMICS G150/G130/S150 chassis and
cabinet units
Practical fault diagnostics exercises

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Training Document 17 - 11 Support and training
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Training Document 17 - 12 Support and training
 The Service & Support Portal provides online access at
www.siemens.com/automation/service&support at any time to comprehensive
information and services covering the full product range of Industry Automation
and Drive Technology.

Online support is divided into two main topics:

Know-how
• Product Support:
Technical information and downloads on products (manuals, FAQ,
software updates, etc.)
• Applications & Tools:
Automation solutions (example solutions, system descriptions,
demonstrations, calculators, tools, etc.)
• Services:
Information on the comprehensive services offered by Service & Support
(contacts, repair, etc.)

Communication
• Forum:
Direct customer-customer communication for technical queries
• Support Request:
Send technical request directly to an expert

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Training Document 17 - 13 Support and training
General The Online Support is always available with a comprehensive information
system with a wide offer. Online Support is always the first step to obtain help
fast, from product support though service information to interactive services.

Product Support In-depth expert knowledge with up-to-date information about our products and
systems provide the basis for the Product Support's expertise in the form of
frequently asked questions, downloads of updates/upgrades for example, up-to-
date product information from marketing/sales, manuals in electronic form as
PDF files, test certificates and characteristic curves.

Application & Tools Applications & Tools is the new platform for solutions and system descriptions in
the Service & Support Portal. Applications & Tools help you to solve your
automation tasks. This support can be obtained in the form of programming
examples and tools, background knowledge, function descriptions, handling
instructions, performance data, etc. The focus here is not on the individual
product; rather, on the interaction between individual products.

Services Shows you the full range of services offered, including detailed information on
our Service & Support processes and a database with details of contact
persons.

Infos Search for the latest brochures on Service & Support – or find out at which trade
show you can meet us in person? All this and more is provided under the
keyword "Infos".

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Training Document 17 - 14 Support and training
Technical forum To augment this comprehensive service offer, we maintain a direct dialog with
specialists using state-of-the art, web-based technology. The new technical
forum is an attractive discussion platform in German and English where users
and experts can exchange information.

Support Request The internet-based Support Request will always provide you with a direct
response to your queries. Outline your situation in online screens. The
Knowledge Base will provide you with appropriate solutions straight away. If the
proposed solution does not match your problem, send the web form directly to
our expert team at Technical Support (hotline).

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Training Document 17 - 15 Support and training
 An intelligent Search function and easy-to-use Navigation system are available
to help you find the desired information:

Search An intelligent and comprehensive search function supplies you with the relevant
results.
• Automatic detection of keywords
• Automatic spell checking
• Automatic sorting of hit list according to relevance

Navigation You can also use the navigation functionality in the product tree to access
the desired information. An index makes for easy product selection.

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Training Document 17 - 16 Support and training
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Training Document 17 - 17 Support and training
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Training Document 17 - 18 Support and training
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Training Document 17 - 19 Support and training