Migration of SIMATIC ET200S FC to SINAMICS drives

SIMATIC ET200S FC FAQ January 2012

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Question

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Question
What must I observe if I wish to replace a SIMATIC ET200S FC converter by a converter from the SINAMICS family? What advantages do I have by making this change?

Answer
To respond to this question with the appropriate amount of detail, follow the instructions and notes listed in this document.

Migration SIMATIC ET200S FC to SINAMICS drives V1.0, Entry ID: 58334334

Table of contents

Table of contents
1 2 Comparison of the ET200S FC with the SINAMICS family............................5 1.1 2.1 2.1.1 2.1.2 3 3.1 3.1.1 3.1.2 3.1.3 3.2 3.3 3.3.1 3.4 3.5 4 4.1 4.2 4.3 4.4 4.5 4.5.1 4.5.2 4.6 5 5.1 5.1.1 5.1.2 5.1.3 5.1.4 5.1.5 5.1.6 5.1.7 5.1.8 5.1.9 5.1.10 5.2 5.2.1 5.2.2 5.2.3 5.2.4 5.2.5 5.3 6 6.1 6.1.1 6.1.2 6.1.3 Selection help for SINAMICS converters............................................6 Design...............................................................................................7 SINAMICS G120C.............................................................................7 SINAMICS G120 ...............................................................................8 Digital inputs......................................................................................9 Fail-safe digital inputs ........................................................................9 Simulating the digital inputs ...............................................................9 Monitoring the load/speed via a digital input..................................... 10 Digital outputs..................................................................................10 Analog inputs...................................................................................10 Simulation of the analog inputs ........................................................ 11 Analog outputs ................................................................................11 Motor holding brake......................................................................... 11 Partner block FB100 (Version 1.x) ................................................... 12 Partner block FB100 (Version 3.0) ................................................... 12 Communication telegrams ............................................................... 12 Routing through a CPU.................................................................... 13 Teleservice......................................................................................14 Teleservice via a CPU ..................................................................... 14 Teleservice directly to the fieldbus ................................................... 15 Slave-to-slave traffic ........................................................................ 15 Changes to ET200S FC................................................................... 16 Elimination of closed-loop control modes ......................................... 16 Changed reference quantities .......................................................... 16 Number of command/drive data sets................................................ 16 Energy recovery (regenerative feedback into the line supply) ........... 16 Braking resistor / braking chopper.................................................... 17 Second ramp function via JOG ramp-function generator .................. 17 U/f points along a characteristic (U/f with programmable characteristic)17 Positioning down ramp has been eliminated .................................... 17 Changes to the phase failure monitoring .......................................... 17 Changes to the free function blocks (FFBs)...................................... 17 New functions when using SINAMICS G120C / G120 ...................... 18 Parameterizing the command and setpoint sources ......................... 18 Fixed setpoints that can be freely used ............................................ 18 Expansion of the motor holding brake function ................................. 18 Speed-dependent controller adaptation............................................ 18 Operating hours counter .................................................................. 18 Memory card ...................................................................................19 Expanded / new safety functions......................................................21 Expansion of SS1 (Safe Stop 1).......................................................21 Expansion of SLS (Safely-Limited Speed)........................................ 22 New safety function SDI (Safe Direction) ......................................... 23 Hardware.........................................................................................................7

IO interface .....................................................................................................9

Communication ............................................................................................12

Parameterization ..........................................................................................16

Safety functions ...........................................................................................20

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Table of contents

6.1.4 6.2 6.2.1 6.2.2 6.3 6.4 6.5 6.6 6.7 7 7.1 7.2 8

New safety function SSM (Safe Speed Monitor)............................... 23 Controlling the safety functions ........................................................ 24 Via F-DIs (local solution).................................................................. 24 Via PROFIsafe ................................................................................25 Changing the reference quantity ...................................................... 27 Group drives....................................................................................27 Simplified parameterization.............................................................. 28 Offline safety parameterization......................................................... 28 Standard STARTER parameterizing screen forms ........................... 28 TRACE............................................................................................29 Acceptance report ...........................................................................29

STARTER parameterizing software ............................................................. 29

Drive fault messages....................................................................................30

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1 Comparison of the ET200S FC with the SINAMICS family

Comparison of the ET200S FC with the SINAMICS family

The ET200S FC is a frequency converter that is integrated in the SIMATIC ET200S system. Communication to the higher-level control is realized via the ET200S head module or is realized directly by the head module with PLC functionality. The ET200S FC does not have its own fieldbus interface.

Frequency converters from the SINAMICS family are available to replace ET200S FC frequency converters. These communicate directly with the higher-level control system via their own fieldbus interface.

Comment: Profinet is being prepared for use with G120C and G120

Migration SIMATIC ET200S FC to SINAMICS drives V1.0, Entry ID: 58334334

1 Comparison of the ET200S FC with the SINAMICS family

1.1

Selection help for SINAMICS converters

The following table is intended to help you select a SINAMICS converter, where in your previous concept you used an ET200S FC.
Previous ET200S FC concept New concept with the SINAMICS family
Replaced by SINAMICS G120C PROFIBUS DP SINAMICS G120 with CU240E-2 DP and PM250 SINAMICS S110 with CU305 DP Multi-axis system SINAMICS S120 Booksize with CU320 and Active Line Module SINAMICS G120C PROFIBUS DP SINAMICS G120 with CU240E-2 DP and PM250 SINAMICS G120 with CU240E-2 DP-F SINAMICS G120 with CU240E-2 DP-F and PM250 SINAMICS S110 with CU305 DP Multi-axis system SINAMICS S120 Booksize with CU320 and Active Line Module Integrated safety technology STO Comments no yes no yes None or externally implemented yes no STO no ICU24F STO / SS1 / SLS yes no yes no yes STO / SS1 / SLS yes

Communication Realized with

Control mode Safety functions used with encoder ? no None or externally implemented

Energy recovery

ICU24

STO / SS1 / SBC

By using the integrated safety functions with encoder, it is possible that external safety relays and contactors can be eliminated

Profibus

STO Additional safety functions without encoder are available

STO / SS1 / SLS / SDI / SSM

with Extended Additional safety functions Safety license without encoder are STO / SS1 / SLS / available SDI / SSM / SBC

no ICU24 yes

None or externally implemented

no yes no

None or externally implemented

yes no

Profinet no

STO yes no ICU24F STO / SS1 / SLS yes no yes STO / SS1 / SLS yes

SINAMICS G120C PROFINET (being prepared) * By using the integrated STO safety functions with SINAMICS G120 with CU240E-2 PN encoder, it is possible that (being prepared) * and PM250 external safety relays and SINAMICS S110 with CU305 PN contactors can be Multi-axis system SINAMICS S120 STO / SS1 / SBC eliminated Booksize with CU320 and Active Line Module SINAMICS G120C PROFINET (being prepared) * STO SINAMICS G120 with CU240E-2 PN (being prepared) * and PM250 SINAMICS G120 Additional safety functions with CU240E-2 PN-F (being prepared) * STO / SS1 / SLS / without encoder are SDI / SSM SINAMICS G120 with CU240E-2 PN-F available (being prepared) * and PM250 SINAMICS S110 with CU305 PN with Extended Additional safety functions Safety license Multi-axis system SINAMICS S120 without encoder are Booksize with CU320 and Active Line STO / SS1 / SLS / available SDI / SSM / SBC Module

* Up to the delivery release for Profinet CU versions, as alternative, the corresponding Profibus CU versions can be used in conjunction with an ET200S master module

The selection criteria involving a motor holding brake is not included in this overview (see Chapter 3.5). Additional help when selecting the SINAMICS converter for your particular application is provided in Catalog SIEMENS D 31 (download via Link). This FAQ predominantly focuses on migrating to a SINAMICS G120C or SINAMICS G120 with CU240E-2. If a control mode is used with an encoder in your application, and it is therefore necessary to use a SINAMICS S110 / S120, then in addition to this FAQ, you can also find additional information in the following FAQ: Migrating SINAMICS G120 with CU240S to SINAMICS S110 with CU305: http://support.automation.siemens.com/WW/view/en/57108654

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2 Hardware

2
2.1

Hardware
Design
Converters belonging to the SINAMICS G family are what are known as standalone devices with their own fieldbus address. A special ET200S environment is not required to operate them. The Profibus devices can be connected to an ET200S CPU via an ET200S master module.

2.1.1

SINAMICS G120C

SINAMICS G120C frame sizes FSA to FSC

G120C with BOP-2 or IOP

SINAMICS G120C is a basic, compact frequency converter for the power range 0.37 kW up to 15 kW (High Overload). The converter can be supplemented by the Basic Operator Panel BOP-2 or the Intelligent Operator Panel IOP. SINAMICS G120C has onboard DI / DO as well as AI / AO, which can be used for internal functions and also as distributed I/O of the PLC. The dimensions of the SINAMICS G120C vary depending on the power rating. Details can be taken from Catalog D 31 (download via Link.

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2 Hardware

2.1.2

SINAMICS G120

SINAMICS G120 frame sizes FSA to FSC

SINAMICS G120 frame sizes FSD to FSF

The modular design of the SINAMICS G120 comprises a CU with BOP-2 or IOP and a Power Module

SINAMICS G120 is a modular frequency converter comprising a Control Unit and Power Module for the power range 0.37kW up to 200kW (PM240, High Overload) or with energy recovery, 5.5kW up to 75kW (PM250, High Overload). The converter can be supplemented by the Basic Operator Panel BOP-2 or the Intelligent Operator Panel IOP. SINAMICS G120 has onboard DI / DO as well as AI / AO, which can be used for internal functions and also as distributed I/O of the PLC. Depending on the power rating and Control Unit being used, the functions and dimensions vary. Details can be taken from Catalog D 31 (download via Link).

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3 IO interface

3
3.1

IO interface
Digital inputs
Contrary to the ET200S FC, converters belonging to the SINAMICS G family have digital inputs; these can be used for internal converter functions as well as distributed I/O of the control system. SINAMICS G120C SINAMICS G120 (CU240E-2) 6 up to 3 (depending on the particular Control Unit)

Number of DI Number of F-DI (each formed from 2 standard DI)

6 up to 1

3.1.1

Fail-safe digital inputs

New function SINAMICS G120C has one, SINAMICS G120 has, depending on the Control Unit, up to 3 two-channel, fail-safe inputs; these can be used to select safety functions integrated in the drive. The F-DIs are formed from two standard DIs. Alternatively, the safety functions can also be selected via PROFIsafe. For details, refer to Chapter 6.

3.1.1.1

Transferring the status of the F-DI via PROFIsafe

Using PROFIsafe, for the CU240E-2 DP-F / PN-F (PN-F is being prepared), the status of the F-DIs can be transferred to the F-CPU in a safety-relevant fashion so that these are available as distributed F I/O. For details, refer to Chapter 6.

3.1.2

Simulating the digital inputs

New function The digital inputs can be simulated for test purposes using the STARTER parameterizing software.

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3 IO interface

3.1.3

Monitoring the load/speed via a digital input

New function (only SINAMICS G120) Using this function, load failure can be monitored as well as a speed deviation (only CU240E-2). For details, refer to the operating instructions Link. SINAMICS G120C does not support this function.

3.2

Digital outputs
Contrary to the ET200S FC, converters belonging to the SINAMICS G family have digital outputs; these can be used for internal converter functions as well as distributed I/O of the control system. SINAMICS G120C SINAMICS G120 (CU240E-2) 3 (2 x relay / 1 x transistor) Max. 30V , 500mA

Number of DO

2 (1 x relay / 1 x transistor) Max. 30V , 500mA

3.3

Analog inputs
Contrary to the ET200S FC, converters belonging to the SINAMICS G family have analog inputs. The analog inputs can be used as additional digital inputs. SINAMICS G120C SINAMICS G120 (CU240E-2) 2 -10 +10V or 0/4 20mA Can also be used as additional DI

Number of AI Type

1 -10 +10V or 0/4 20mA Can also be used as additional DI

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3 IO interface

3.3.1

Simulation of the analog inputs

New function The analog inputs can be simulated for test purposes using the STARTER parameterizing software.

3.4

Analog outputs
Contrary to the ET200S FC, converters belonging to the SINAMICS G family have analog outputs. SINAMICS G120C SINAMICS G120 (CU240E-2) 2 0 10V or 0/4 20mA

Number of AI Type

1 0 10V or 0/4 20mA

3.5

Motor holding brake

To control the motor holding brake, for the ET200S FC, the Brake Control Module xB1 (24V DC brake) or xB2 (230V 400V 1AC 50Hz) was required. In conjunction with the G120C or the G120 this is no longer required. SINAMICS G120C A 24V DC motor holding brake can be controlled via one of the two digital outputs (max. 500mA) of the SINAMICS G120C. A coupling/interface relay is required for a motor holding brake with a higher voltage/current. For details, refer to the operating instructions Link. SINAMICS G120 The motor holding brake is preferably controlled via the Brake Relay (max. 30V DC / 12A, 440V AC / 3.5A), which is directly connected to the Power Module of the SINAMICS G120. For details refer to the operating instructions Link.

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4 Communication

Communication
Existing programs for the communication between an ET200S FC and a PLC can still be used or must be revised depending on the version/release of the previously used ET200S FC. However, the PLC program used for communication can also be simplified. This is because, contrary to the ET200S FC, for the SINAMICS G family, more powerful communication telegrams (see Chapter 4.3) and cyclic communication are now available.

4.1

Partner block FB100 (Version 1.x)

Existing programs with the partner block FB100 (Version V1.x) to control an ET200S FC from an ET200S head module or from a PLC via the fieldbus can no longer be used for the SINAMICS G family. In this case, the FB100 must be replaced by version V3.0 Link and/or the parameter block can be omitted (no longer used).

4.2

Partner block FB100 (Version 3.0)

If the FB100 with version 3.0 is already being used in your program, then this can also be used for converters belonging to the SINAMICS G family. If the parameters are read or written via the FB100, then as result of the changed parameter numbers, the PLC program must be appropriately modified and adapted. However, the FB100 is not absolutely necessary, as SINAMICS G converters can be conventionally accessed via cyclic and acyclic communication.

4.3

Communication telegrams
Communication telegrams that are available 1 (PZD-2/2) 20 (PZD-2/6) 350 (PZD-4/4) 352 (PZD-6/6) 353 (PZD-2/2, PKW-4/4) 354 (PZD-6/6, PKW-4/4)

999

ET200S FC (FW1.x) ET200S FC (FW3.x) SINAMICS G120C SINAMICS G120 X X X X X

FB100 (V1.x) absolutely necessary

X X X

X X

X X

X X

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4 Communication

4.4

Routing through a CPU

For an ET200S FC with Firmware V1.x, routing beyond network limits (e.g. IE to Profibus DP) is not possible. In this case, only point-to-point communication via the RS232 port of the ICU24 is possible. The routing functionality of the ET200S FC with Firmware V3.0 is still also available for SINAMICS G120C / G120. For routing beyond network limits (e.g. IE to Profibus DP), the CPU must support the routing protocol data set. In addition, just as before, DriveES Basic is required. The following CPUs support data set routing: ET200S IM151-8 PN/DP CPU in conjunction with the DP master module SIMATIC S7-300 CPU313C-2 DP CPU314C-2 DP CPU315-2 DP CPU315-2 PN/DP CPU317-2 DP CPU317-2 PN/DP CPU319-3 PN/DP SIMATIC S7-400 CPUs WinAC RTX from version V3.3 from version V3.3 from version V3.0 from version V3.1 from version V3.3 from version V3.1 from version V2.7 from version V5.1 from version 2010, update 1 with CP5603, CP5613 or CP5623

CPU314C-2 PN/DP from version V3.3

Presently, the following systems do not support data set routing: SIMATIC S7-1200 WinAC MP SIMOTION

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4 Communication

4.5
4.5.1

Teleservice
Teleservice via a CPU

A Teleservice Adapter II and a CPU, which is listed under Routing (Chapter 4.4) and which supports data set routing, are required.

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4 Communication

4.5.2

Teleservice directly to the fieldbus

With this configuration, the Teleservice Adapter is directly connected to the fieldbus. This is why it is of no significance that the CPU supports data set routing. Presently, not possible with Profibus. Presently, the Teleservice Adapter II does not support this functionality. For Profinet, with a SINAMICS G120C PN or G120 with PN-CU (both are being prepared), it is possible using the Teleservice Adapter IE Basic.

4.6

Slave-to-slave traffic
New function With "slave-slave communication" also known as "Data Exchange Broadcast" fast data exchange is possible between the converters (slaves) without the master being directly involved; for instance, to enter the actual value of one converter as setpoint for the other converter (for more detailed information, see SINAMICS G120C Operating Instructions Link or SINAMICS G120 Operating Instructions Link).

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5 Parameterization

Parameterization
It is not possible to directly migrate from ET200S FC STARTER projects to SINAMICS G as a result of the modified parameter structure. The drive must be recommissioned using BOP-2, IOP or STARTER.

5.1
5.1.1

Changes to ET200S FC
Elimination of closed-loop control modes
As the SINAMICS G family has no speed encoder interface, only the encoderless (sensorless) closed-loop control modes are available (U/f, Sensorless Vector Control (SLVC) and encoderless closed-loop torque control). However, the sensorless vector control (SLVC) has been significantly improved in the SINAMICS G120C and G120 when compared to the closed-loop control in the ET200S FC. However, in spite of this, if a control mode is required with an encoder, then the CU305 (SINAMICS S110) Link or the SINAMICS S120 use

5.1.2

Changed reference quantities

The reference quantities (p2000 2004) apply in the SINAMICS family as standard for all data sets. In addition, the reference quantities have been expanded by the reference temperature (p2006). In the SINAMICS family, the speed setpoint and actual value no longer refer to Hz but to rpm; this means that it is no longer necessary to convert the required speed into a frequency. In the SINAMICS family, parameter p640 (ET200S FC: motor overload factor in %) has been changed to the current limit in Arms.

5.1.3

Number of command/drive data sets

SINAMICS G120C 2 command data sets (CDS) and 1 drive date set (DDS) are available in SINAMICS G120C. The second command data set must be enabled using parameter p170 SINAMICS G120 There are up to 4 command data sets (CDS) and up to 4 drive data sets (DDS) available in the CU240E-2. Contrary to the ET200S FC, these must now first be enabled using parameter p170 (CDS) or p180 (DDS).

5.1.4

Energy recovery (regenerative feedback into the line supply)

Contrary to the ET200S FC, SINAMICS G120C does not support regenerative feedback into the line supply (energy recovery). SINAMICS G120 supports energy recovery in conjunction with the Power Module PM250.

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5 Parameterization

5.1.5

Braking resistor / braking chopper

For the SINAMICS G120C and SINAMICS G120, in conjunction with the PM240, the braking chopper is automatically activated. The braking resistor must be externally protected against overload (see SINAMICS G120C Operating Instructions Link or SINAMICS G120 Operating Instructions Link and Hardware Installation Manual PM240 Link).

5.1.6

Second ramp function via JOG ramp-function generator

It is no longer possible to use the JOG ramp-function generator to implement a second ramp function. However, when using the data set changeover (DDS), up to 4 different parameterizable ramp functions are now available. The data set changeover can be implemented in operation via digital inputs or via the fieldbus. For details, refer to the operating instructions Link. SINAMICS G120C has no data set changeover (DDS).

5.1.7

U/f points along a characteristic (U/f with programmable characteristic)

Contrary to the ET200S FC (3 voltage points / frequency points along a characteristic (p1320 p1325)), the SINAMICS G family has 4 voltage / frequency points (p1320 p1327), which means that the characteristic can be more finely parameterized. If the additional points are not required, then set points 3 and 4 to the same value.

5.1.8

Positioning down ramp has been eliminated

The positioning down ramp available in the ET200S FC (parameters p2480 p2488) is no longer available in the SINAMICS family. Implemented using a rapid traverse/crawl switchover based on FFBs (an FAQ is being drawn up) or using a SINAMICS S110 with EPOS (basic positioner).

5.1.9

Changes to the phase failure monitoring

Contrary to ET200S FC, the phase failure monitoring (ET200S FC, p291) is always active for the SINAMICS family and cannot be deactivated.

5.1.10

Changes to the free function blocks (FFBs)

The scope and functionality of the free function blocks have been significantly expanded when compared to the ET200S FC and now, as a result of the onboard I/Os, can be better used. As a result of the expanded functionality, it was necessary to shift the parameter numbers. Presently, the FFBs can only be interconnected via the expert list. For details, refer to the List Manual Link. SINAMICS G120C does not have any FFBs.

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5 Parameterization

5.2
5.2.1

New functions when using SINAMICS G120C / G120

Parameterizing the command and setpoint sources
In the drive, the corresponding macros can be selected via p15 (e.g. during the quick commissioning), via which the interfaces (command source, setpoint source, I/O interconnection) can be adapted to the corresponding application far faster than before. Simplified parameterization. For details, see SINAMICS G120C Operating Instructions Link or SINAMICS G120 Operating Instructions Link.

5.2.2

Fixed setpoints that can be freely used

Fixed setpoints that can be freely used can be defined in p2900 / p2901 (+/100.00%) and p2930 (+/- 100000.00 Nm). In addition, fixed setpoints that are already defined are available in r2902 [0 14].

5.2.3

Expansion of the motor holding brake function

Only SINAMICS G120 The functionality of the motor holding brake known from the ET200S FC, has been expanded in the SINAMICS G120. Various modes are now available, where the brake, as before, can be opened or closed from the process, but now also permanently or as a function of an external signal. The functionality of the SINAMICS G120C brake control is comparable with that of the ET200S FC.

5.2.4

Speed-dependent controller adaptation

Only SINAMICS G120 The Tn and Kp components of the controller can now be adapted as a function of the speed in the CU240B/E-2 (refer to the List Manual Link, function diagram 6050).

5.2.5

Operating hours counter

Only SINAMICS G120 For the CU240B/E-2, the actual operating hours can be read out of p650 and a maintenance interval can be activated in p651. Alarm A1590 is activated after the time in p651 has expired.

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5 Parameterization

5.3

Memory card
Contrary to the ET200S FC (only MMC), for the SINAMICS G family, MMC and SD cards can be used. Just as before, the use of a memory card is optional. Transferring a project from an ET200S FC into SINAMICS Projects of an ET200S FC on an MMC card cannot be transferred into a SINAMICS G as a result of the changed parameter structure. Clear the memory card and write the SINAMICS G project to it Handling memory cards Writing data to an MMC / SD card has been significantly simplified for the SINAMICS G family. Parameter changes are automatically saved to the memory card. For details, see the SINAMICS G120C Operating Instructions Link, SINAMICS G120 Operating Instructions Link or FAQ Link.

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6 Safety functions

Safety functions
The safety functions known from the ET200S FC have been expanded. The following table provides an overview of the available safety functions and how they are possibly controlled.
Device family ET200S FC G120C G120 CU240E-2 DP ICU24F Control Unit Firmware basis Standards: EN 954-1 IEC 61508 ISO 13849-1 Functions: STO SS1 SSM SDI SLS No. of SLS limit values SBC Safety control: F-DI No. of F-DI CU240E-2 CU240E-2 DPF CU240E-2 F CU240E-2 PNCU240E-2 PN F (being (being prep.) prep.) FW4.4

FW3.0

Cat. 3 SIL 2 Pld yes yes no no yes 1 no no 0 yes no no no no 0 no yes up to 1 yes no no no no 0 no yes up to 1 yes no no no no 0 no yes up to 1 yes yes no yes yes 1 no yes up to 3 yes yes yes yes yes 4 no yes up to 3

PROFIsafe F-DI and PROFIsafe together F-DI status via PROFIsafe (telegram 900):

yes Using PM-D (G120C DP PROFIsafe and PN (being prepared)) no yes

no

yes

no

yes

no

yes

no

yes only STO via F-DI)

no

no

no

no

no

yes

Information: Just as before, speed acquisition using a speed encoder is not required for these safety functions. STO is permissible for all applications, where Emergency Stop functionality is required. SS1, SLS, SSM and SDI are not permissible for loads that drive the motor and loads that are permanently in the generator mode. The F-DIs are formed by combining 2 standard DIs through the appropriate parameter assignment (also see Chapter 3.1). The G120C PN as well as the Profinet CUs CU240E-2 PN and CU240E-2 PN-F are being prepared and will be available soon.

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6 Safety functions

More detailed information on the safety functions is provided in the Safety Integrated Function Manual Link or on the following Internet page Link.

6.1
6.1.1

Expanded / new safety functions

Expansion of SS1 (Safe Stop 1)

Expansion for ET200S FC The SS1 safety function was extended as follows when compared to the ET200S FC: Braking the motor after activating SS1 can now be set using the following parameter assignment: Brake ramp monitoring (comparable with ET200S FC): After selecting SS1, the drive automatically brakes along the OFF3 ramp. The deceleration is monitored using the SBR ramp (Safe Brake Ramp). STO is activated when standstill is reached Acceleration monitoring: After selecting SS1, the drive does not decelerate along the OFF3 ramp, but can be independently decelerated. The speed is safely monitored to ensure that the drive does not accelerate When the "shutdown velocity/speed SS1 is reached, or after the "SS1 delay time" has expired, then STO is activated The SS1 ramp time (brake ramp monitoring mode) was increased, for the ET200S FC, from 99s (referred to 200Hz) in the SINAMICS family to 1000s (referred to the reference speed, e.g.1500 rpm). Safely and reliably stopping high moments of inertia.

Changes to ET200S FC For the ET200S FC, it was possible to interrupt/cancel SS1 by withdrawing the SS1 request before reaching the SS1 standstill detection frequency. This is no longer possible for the SINAMICS family. The SS1 request remains active until STO is internally activated.

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6 Safety functions

6.1.2

Expansion of SLS (Safely-Limited Speed)

Expansion for ET200S FC The SLS safety function was extended as follows when compared to the ET200S FC: The various SLS modes of the ET200S FC have been integrated in the SINAMICS family into one "mode". Simplify commissioning and the possibility of implementing new safety concepts With the SINAMICS G120 Control Units CU240E-2 DP F and CU240E-2 PN-F (being worked on), for control via PROFIsafe, there are now 4 SLS limit values available that can be parameterized. New safety concepts can be implemented SLS can already be activated at standstill. After SLS has been activated, current must be fed into the motor within 5 seconds. For the CU240S family, it is not necessary that a minimum speed is reached within these 5 seconds. Simplification of the control and implementation of new safety concepts, for example, safe setting-up operation possible The behavior of the SINAMICS G120 when activating SLS (automatic or manual speed reduction) can be set using the SS1 brake ramp or acceleration monitoring. The response to a limit value violation when SLS is activated can be selected to be STOP A (STO) and STOP B (SS1) (ET200S FC, only STO possible). In the case of a fault, the motor can now be safely braked and no longer coasts down unbraked.

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6 Safety functions

6.1.3

New safety function SDI (Safe Direction)

This safety function prevents the motor being operated in an unsafe direction of rotation. A speed encoder is not required for this safety function. New safety concepts can be implemented, for example, staying in a hazardous/dangerous area while a part of the system is being moved out of this hazardous/dangerous area or setting-up operation with a safely inhibited direction of rotation More details on this safety function can be found in the Safety Integrated Function Manual Link or on the following Internet page Link.

6.1.4

New safety function SSM (Safe Speed Monitor)

A PROFIsafe signal is used to indicate that the motor speed is below a parameterized speed limit. When the speed limit is exceeded, this signal is deactivated; however, the converter does not respond to this. A speed encoder is not required for this safety function For example, using this signal, an F-CPU can release a protective door. As long as the parameterized SSM limit speed/velocity is not exceeded, the door is released. After the door has been opened and the motor speed increases above the SSM speed limit, the F-CPU activates a safe shutdown of the SINAMICS G120 via STO or SS1. More detailed information on this safety function is provided in the Safety Integrated Function Manual Link on the following Internet page Link.

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6 Safety functions

6.2

Controlling the safety functions

The safety functions all the ET200S FC were controlled from a safe ET200S Power Module (PM-D F X1 or PM-D PROFIsafe) via 2 of 6 safety-related buses in the backplane bus on the ICU24F. For SINAMICS converters, the safety functions are directly controlled via F-DIs or PROFIsafe.

6.2.1

Via F-DIs (local solution)

For ET200S FC, the safety sensors were not able to be directly connected. Here, the necessary intermediate safety relays and PM-D F X1 where required. SINAMICS G120C has one F-DI, G120 has 3 F-DIs, which are created from two standard DIs. Safety sensors can be directly connected to these F-DIs. Details on interconnecting the sensors are provided in the Safety Integrated Function Manual Link . Safety functions via F-DIs ET200S FC SINAMICS G120C / G120 The safety sensors are directly read-in via FDIs. Intermediate safety relays are not required.

The safety sensors are evaluated by the safety relays and read-in via the PM-D F X1. The safety functions in the ET200S FC are selected via two safety-related buses in the backplane bus.

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6 Safety functions

6.2.2

Via PROFIsafe
Contrary to the ET200S FC where a PM-D PROFIsafe was required, for SINAMICS G120C and G120, the safety functions can be directly selected via PROFIsafe in the converter. Further, in the PROFIsafe status word, the status of the safety functions are safely transferred to the F-CPU and can be used there, for example, as enable signal for an access door. In order to be able to use the safety functions of the SINAMICS G120C or G120, the existing ET200S FC safety program of the F-CPU must be appropriately adapted/expanded. Safety functions via PROFIsafe ET200S FC SINAMICS G120C / G120 The safety functions are directly selected and the status signaled back via the fieldbus interface of the SINAMICS G120C / G120.

In the ET200S head module, the PROFIsafe telegram is evaluated and is transferred from PM-D PROFIsafe via the 6 safety-relevant buses in the backplane bus. The safety functions in the ET200S FC are selected via two safety-related buses.

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6 Safety functions

6.2.2.1

ET200S FC
The safety functions of the ET200S FC were controlled via the safety-related buses SG 1 SG 6. To select the safety function STO / SS1, safety-related buses SG 1 5 were able to be appropriately parameterized. The SLS safety function was permanently connected to safety-related bus SG 6. It was not possible to feed back the status of the safety functions.

6.2.2.2

SINAMICS G120C and G120

The assignment of the signals in the PROFIsafe telegram to the safety functions of the converter are fixed, contrary to ET200S FC. The status of the safety functions is signaled back to the F-CPU in a safety-related fashion. The structure of the PROFIsafe telegrams of the individual SINAMICS G converter will now be explained. More details regarding the control of the safety functions via PROFIsafe, can be found in the Safety Integrated Function Manual Link. SINAMICS G120C PROFIsafe telegram 30 Relevant for SINAMICS G120C DP and G120C PN (being worked on)

SINAMICS G120 PROFIsafe telegram 30 Relevant for SINAMICS G120 with CU240E-2 family

* Extended Safety functions (only CU240E-2 DP-F and CU240E-2 PN-F (being worked on))

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6 Safety functions

SINAMICS G120 PROFIsafe telegram 900 Relevant for SINAMICS G120 with CU240E-2 DP-F and CU240E-2 PN-F (being worked on) The PROFIsafe telegram 900 differs from the PROFIsafe telegram 30 in so much, that for this telegram, the status of the fail-safe digital inputs is also transferred (byte 3, bit 02), so that these are then available to the F-CPU as distributed FI/O.

6.3

Changing the reference quantity

The speed-referred safety values no longer refer to Hz, but to rpm. Further, a gear factor can now be parameterized As a consequence, it is no longer necessary to convert between the parameterization and the resulting motor speed.

6.4

Group drives
ET200S FC The STO, SS1 and SLS safety functions can also be used in conjunction with group drives (when more than one motor is connected and operated with one converter). SINAMICS G120C and G120 The STO safety function can be used in conjunction with group drives (when more than one motor is connected and operated with one converter). The additional safety functions (SS1, SLS, SDI and SSM) have presently still not been released for group drives.

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6.5

Simplified parameterization
New function Just the same as for the SINAMICS S110 and S120, parameterization is performed in one channel, and only at the end of the commissioning phase, is it duplicated to the second channel by pressing a button. As a consequence, it is no longer necessary to enter safety parameters through two channels (for instance Hz and kHz). Further, it is no longer necessary to confirm the checksum. This simplifies commissioning and avoids incorrect parameter assignments

6.6

Offline safety parameterization

New function Just the same as for the SINAMICS S110 and S120, it is now also possible to parameterize the safety functions offline. Safety parameterization can already be prepared in an office environment.

6.7

Standard STARTER parameterizing screen forms

New function The STARTER parameterizing screen forms are now the same as the parameterizing screen forms of the SINAMICS S110 and S120. It is no longer necessary to get to know a new system when changing over to a different SINAMICS converter

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7 STARTER parameterizing software

7
7.1

STARTER parameterizing software

TRACE
New function Contrary to the ET200S FC, for the SINAMICS family, STARTER has a trace function to optimize drives.

7.2

Acceptance report
New function Using the STARTER parameterizing software, an acceptance report for the safety functions can be generated; all of the relevant parameter values are automatically entered into this report. This can be found in STARTER under the drive unit in the folder Documentation

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8 Drive fault messages

Drive fault messages

The drive fault messages/signals of the SINAMICS family have changed when compared to the ET200S FC. If the fault texts are to be displayed on an HMI for diagnostic purposes, then the corresponding fault texts can be downloaded under the following Link

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