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Siemens SINAMICS G115D User Manual
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12.3.31.4
Parallel shaf
t gearbo
x
.
.
.
.
.
.
Figure12-45
Mounting positions for parallel shaft gearbox F
.AD shaf
t-mounted design, size29
Additional information on t
he SIMOGEAR geared mot
or
12.3
Specic
data gearbox
SINAMICS G115D Wall Mount
ed distributed drive
Operating Instructions, 07/2023, FW V4.7 SP14, A5E52808211A AA
537
538
540
Table of Contents
Preface
5
Table of Contents
7
Changes in the Manual
17
Fundamental Safety Instructions
19
General Safety Instructions
19
Equipment Damage Due to Electric Fields or Electrostatic Discharge
25
Warranty and Liability for Application Examples
25
Cybersecurity Information
25
Residual Risks of Power Drive Systems
27
Overview of the SINAMICS G115D Drive
29
System Overview
29
Scope of Delivery
30
SINAMICS G115D Wall Mounted
30
Directives and Standards
35
Optional Components
36
External Braking Resistor
36
Connectors
37
Glanded Installation Kit
38
Connector Cover Kit
38
SINAMICS G120 Smart Access
39
SAM Interface Kit
39
Mounting
41
Mounting the G115D Wall Mounted Drive
41
Mounting the Optional Components
44
Mounting the External Braking Resistor
44
Mounting the SINAMICS G120 Smart Access
46
Wiring
51
EMC Installation Guidelines
51
Connections and Interference Suppression
51
Basic EMC Rules
51
Equipotential Bonding
52
Permissible Line Supplies
54
TN Line System
55
TT Line System
55
Line System
56
Requirements for the Protective Conductor
59
Requirements for Branch Circuit Protection
60
Operation with Residual Current Protective Device (RCD)
60
Forming DC Link Capacitors
61
Overview of the Converter Interfaces
62
Overview
62
Cables and Connectors
66
Maximum Permissible Cable Length
67
Cable Cross-Sections and Cable Lugs
68
Connecting the Line Supply
71
Interface Description - X1/X3
71
Connecting to the Line Supply Using Daisy Chain
73
Connecting the Motor
75
Interface Description - X2
76
Connecting the Motor in a Star or Delta Connection
77
Overview
77
Configuring the Star/Delta Connection of the Wall-Mounted Converter
79
Connecting the 24 V Power Supply
79
Interface Description - X01/X02
79
Connecting to the 24 V Power Supply Using Daisy Chain
81
Connecting the Digital Inputs and Outputs
83
Interface Description - X07/X08/X05
83
Factory Interface Setting
84
Fail-Safe Digital Input
90
Connecting to PROFINET and Ethernet
91
Interface Description - X150 P1/P2
91
Communication Via PROFINET IO and Ethernet
91
Protocols Used
92
Connecting the Converter to PROFINET
94
What Do You Have to Set for Communication Via PROFINET
94
Installing GSDML
95
Connecting the Converter to Ethernet/Ip
96
What Do You Need for Communication Via Ethernet/Ip
96
Connecting to AS-I
97
General Information
97
Interface Description - X03
98
Setting the Address
98
Using the AS-I Programmer
100
Connecting to SINAMICS G115D I/O Variant
102
Grounding the Converter Housing
102
Connecting the External Braking Resistor
103
Connection Examples
105
Commissioning
107
Commissioning Guidelines
107
Commissioning Tools
108
Preparing for Commissioning
109
Factory Settings
109
Collecting Motor Data
111
Selecting U/F Control or Speed Control
113
Calculating Maximum Speed for Permanent Magnet Synchronous Motors
114
Quick Commissioning
115
Quick Commissioning with DIP Switches
115
Quick Commissioning with a PC (Startdrive)
118
Creating a Project
119
Integrating the Converter into the Project
119
Starting the Commissioning Wizard
121
Carrying out Quick Commissioning
121
Identifying Motor Data
123
Quick Commissioning with the SINAMICS G120 Smart Access
125
Self-Optimization of the Speed Control
126
Saving the Settings in the Converter (RAM → EEPROM)
126
Restoring the Factory Settings
127
Restoring the Factory Settings/Delivery Condition (Without Safety Functions)
128
Resetting the Safety Functions to the Factory Settings
129
Advanced Commissioning
131
Overview of Converter Functions
131
Sequence Control When Switching the Motor on and off
133
Adapt the Default Settings of the Inputs and Outputs
135
Overview
135
Digital Inputs
136
Digital Outputs
137
Controlling Clockwise and Counter-Clockwise Rotation Via Digital Inputs
138
Two-Wire Control, Method 1
139
Two-Wire Control, Method 2
140
Two-Wire Control, Method 3
141
Three-Wire Control, Method 1
142
Three-Wire Control, Method 2
143
Drive Control Via PROFINET
144
Receive Data and Send Data
144
Telegrams
145
Control and Status Word 1
147
Control and Status Word 3
149
Control and Status Word G115D
150
NAMUR Message Word
152
Parameter Channel
152
Expanding or Freely Interconnecting Telegrams
156
Acyclically Reading and Writing Converter Parameters
158
Drive Control Via Ethernet/Ip
159
Configuring Communication Via Ethernet/Ip
159
Supported Objects
162
Supported ODVA AC/DC Assemblies
173
Creating Generic I/O Module
174
The Converter as Ethernet Node
175
Drive Control Via AS-I
175
Single Slave Mode
175
Dual Slave Mode
177
Assignment Tables
180
Cyclic and Acyclic Communication Via CTT2
182
Cyclic Communication
183
Acyclic Communication - Standard
184
Acyclic Communication - Manufacturer-Specific
184
Jogging
186
Conveyor Technology Control Functions (for G115D PROFINET and AS-I Variants Only)
187
Conveyors
188
Conveyor, One Direction and One Speed (P3393 = 1)
188
Conveyor, One Direction and Two Speeds (P3393 = 2)
190
Conveyor, Two Directions and One Speed (P3393 = 3)
192
Conveyor, Two Directions and Two Speeds (P3393 = 4)
194
Turntables
196
Turntable, Two Positions and One Speed (P3393 = 5)
197
Turntable, Two Positions and Two Speeds (P3393 = 6)
200
Turntable, Three Positions and One Speed (P3393 = 7)
204
Turntable, Three Positions and Two Speeds (P3393 = 8)
207
Corner Turntable Lifts
210
Corner Turntable Lift, Two Positions and One Speed (P3393 = 9)
211
Corner Turntable Lift, Two Positions and Two Speeds (P3393 = 10)
214
Travelling Trolleys
216
Travelling Trolley, One Speed (P3393 = 11)
217
Travelling Trolley, Two Speeds (P3393 = 12)
219
Conveyor Technology Control Parameters
222
Switching over the Drive Control (Command Data Set)
224
7.11 Motor Holding Brake
226
Encoder Interface
231
Free Function Block
232
Selecting Physical Units
232
Motor Standard
232
System of Units
233
Technological Unit of the Technology Controller
234
Setting the System of Units and Technology Unit
235
Safe Torque off (STO) Safety Function
235
Function Description
236
Commissioning STO
238
Commissioning Tool
238
Safety Function Password
238
Configuring a Safety Function
239
Interconnecting the "STO Active" Signal
240
Setting the Filter for Fail-Safe Digital Inputs
241
Setting the Forced Checking Procedure (Test Stop)
244
Finalizing Online Commissioning
245
Checking the Interconnection of Digital Inputs
247
Acceptance - Completion of Commissioning
248
Safely Limited Speed (SLS)
249
Setpoints
257
Overview
257
Specifying the Setpoint Via the Fieldbus
258
Electromechanical Potentiometer
259
Motorized Potentiometer as Setpoint Source
260
Fixed Speed Setpoint as Setpoint Source
264
Setpoint Processing
267
Overview
267
Invert Setpoint
268
Inhibit Direction of Rotation
269
Skip Frequency Bands and Minimum Speed
270
Speed Limitation
271
Ramp-Function Generator
272
PID Technology Controller
277
Motor Control
284
Setting the Saturation Characteristic of the Permanent Magnet Synchronous Motor (Third-Party Motor)
284
U/F Control
286
Characteristics of U/F Control
287
Selecting the U/F Characteristic
288
Optimizing Motor Starting
289
Sensorless Vector Control with Speed Controller
291
Structure of Vector Control Without Encoder (Sensorless)
291
Optimizing the Closed-Loop Speed Controller
293
Advanced Settings
295
Optimizing the Operation of the Permanent Magnet Synchronous Motor
297
Friction Characteristic
299
Moment of Inertia Estimator
301
Pole Position Identification
308
Torque Control
310
Electrically Braking the Motor
311
DC Braking
312
Dynamic Braking
315
Overcurrent Protection
317
Converter Protection Using Temperature Monitoring
318
Motor Temperature Monitoring Using a Temperature Sensor
322
Motor Protection by Calculating the Temperature
325
Motor and Converter Protection by Limiting the Voltage
327
Monitoring the Driven Load
329
Load Monitoring
329
Rotation Monitoring
330
Torque Monitoring
331
Blocking Protection, Leakage Protection and Dry-Running Protection
333
7.28 Efficiency Optimization
336
Calculating the Energy Saving for Fluid Flow Machines
339
Switchover between Different Settings
342
Activating Licensed Functions
344
Licensing
344
Creating or Displaying the License Key
345
Writing the License Key to the Card
347
Recommended Memory Cards
349
Data Backup and Series Commissioning
353
Transferring Settings Using a Memory Card
354
Memory Cards
354
Converter → Memory Card
355
Memory Card → Converter
357
Activating Message for a Memory Card that Is Not Inserted
359
Transferring Settings Using a PG/PC
360
Converter → PG/PC
360
PG/PC → Converter
361
Other Ways to Back up Settings
363
Write Protection
363
Know-How Protection
364
Extending the Exception List for Know-How Protection
366
Activating and Deactivating Know-How Protection
368
Alarms, Faults and System Messages
371
Status LED Overview
371
System Runtime
375
Identification & Maintenance Data (I&M)
375
Alarms, Alarm Buffer, and Alarm History
376
Faults, Fault Buffer and Fault History
380
List of Alarms and Faults
383
Corrective Maintenance
389
Spare Parts Compatibility
389
Replacing the Converter
390
Replacing the Converter Hardware
390
Replacing a Converter with Active Know-How Protection
392
Replacing a Converter with Know-How Protection Without Copy Protection
392
Replacing a Converter with Know-How Protection with Copy Protection
392
Replacing the Spare Parts
394
Spare Parts Overview
395
Replacing the Electronic Module
396
Replacing the Fan Unit
398
Repair Switch
400
Local/Remote Control Panel
401
Firmware Upgrade and Downgrade
403
Preparing the Memory Card
405
Upgrading the Firmware
405
Downgrading the Firmware
408
Correcting an Unsuccessful Firmware Upgrade or Downgrade
410
Reduced Acceptance Test after Component Replacement and Firmware Change
411
Technical Data
413
Technical Data of the G115D Wall-Mounted Converter
413
General Converter Technical Data
413
Technical Data of Inputs and Outputs
415
Technical Data Dependent Upon the Power
415
Technical Data of Braking Resistors
417
Load Cycles and Overload Capabilities
419
Derating Data
420
Torque Derating as a Function of the Installation Altitude
420
Current Derating as a Function of the Surrounding Temperature
421
Torque Derating as a Function of the Line Voltage
421
Current Derating as a Function of the Pulse Frequency
422
Derating of Motor Cable Length Based on Pulse Frequency and Surrounding Temperature
423
Low Frequency Operation
423
Data Regarding the Power Loss in Partial Load Operation
424
Electromagnetic Compatibility of the Converter
424
Protecting Persons from Electromagnetic Fields
426
Additional Information on the SIMOGEAR Geared Motor
429
General Information Geared Motor with SINAMICS G115D Motor Mounted / Wall Mounted
429
Specific Hazard Types and Fundamental Obligations
429
Rating Plate
430
Surface Treatment
430
General Information on Surface Treatment
430
Painted Version
431
Primed Version
433
Incoming Goods
433
General Information on Transport
434
Unpacking
435
General Information Concerning the Installation
435
Installation Notes
437
Thread Sizes and Tightening Torques for Fastening Bolts
438
Operation
439
Cleaning the Geared Motor
439
Inspecting the Geared Motor
440
Disposal
440
Technical Data
441
Type Designation Motor and Converter
441
Gearbox Type Designation
442
General Technical Data
443
Rating Plate for Geared Motors with SINAMICS G115D Motor Mounted
444
Rating Plate for Geared Motors with SINAMICS G115D Wall Mounted
445
Weight
446
Sound Energy Level
446
Spare Parts
447
Stocking of Spare Parts
447
Spares on Web
448
Specific Data Motor
449
General Motor Information
449
Use as Prescribed
449
General Technical Description
450
Cooling
451
Terminal Box and Application Box
451
Fastening for Suspended Transport
452
Storage
452
Installation Conditions for the Motor
453
Condensation Drain Hole (Optional)
454
Connecting the Motor in the Terminal Box
454
General Notes for Motor Connection (Wall Mounted)
455
Terminal Box
456
Terminal Marking
457
Direction of Rotation
457
Connecting the Cables in the Terminal Box
458
External Grounding
459
Mounting and Installation (Wall Mounted)
459
Converter Operation
461
Checking the Insulation Resistance (Wall Mounted)
462
Commissioning the Motor
463
Faults, Causes and Remedies
465
General Notes about Maintenance
466
Locking the Manual Release of the Brake (Optional)
467
Lubrication
467
Checking the Tightness of Fastening Bolts
469
Inspection of the Motor
469
Servicing the Brake
469
Wear of the Spring-Operated Brake
469
Maintenance Intervals for the Brake
470
Adjusting the Air Gap
471
Replacing the Friction Lining
473
Circuit Diagrams
474
Spare Parts List, Motor
476
Motor Frame Sizes 71 - 132
476
Brake
480
Specific Data Gearbox
481
General Information Gearbox
481
Use for the Intended Purpose
482
General Technical Description
482
Shaft Seals
483
Cooling
484
Fastening for Suspended Transport
485
Storage
486
General Information for Storage
486
General Notes for Storage up to 36 Months
487
Gearbox Filled with Operating Oil and Anti-Corrosive Agent
487
Gearbox Completely Filled with Oil
487
Gearbox with Foot Mounting
488
Gearbox with Flange Mounting
488
Gearboxes in Foot or Flange Version
489
Mounting an Input or Output Element on the Gearbox Shaft
490
Removing and Installing the Protection Cover
492
General Information on Installing the Shaft-Mounted Gearbox
493
Hollow Shaft with Feather Key
494
Mounting the Hollow Shaft with Parallel Key
494
Removing the Hollow Shaft with Parallel Key
495
Hollow Shaft with Shrink Disk
497
Mounting the Hollow Shaft with Shrink Disk
497
Mounting the Shrink Disk
498
Pulling off the Shrink Disk
500
Cleaning and Lubricating Shrink Disks
500
SIMOLOC Assembly System
501
General Notes for the SIMOLOC Assembly System
501
Installing SIMOLOC
503
Removing SIMOLOC
505
Hollow Shaft with Splines
506
Torque Arms with Slip-On Gearboxes
507
General Information Regarding Torque Arms
507
Mounting Torque Arms on Parallel Shaft Gearboxes
507
Mounting Torque Arms on Bevel Gearboxes and Helical Worm Gearboxes
508
General Information about Commissioning
509
Checking the Oil Level Prior to Commissioning
510
Mounting the Oil Expansion Tank
510
Faults, Causes and Remedies
512
General Notes about Maintenance Work
514
Checking and Changing Lubricants
516
General Safety Instructions
516
Checking the Oil Level
517
Checking the Oil Level Using the Oil Sight Glass (Optional)
518
Checking the Oil Level Using the Oil Dipstick (Optional)
518
Checking the Oil Quality
519
General Safety Notes for Changing the Oil
520
Draining the Oil
520
Flushing the Gearbox When Changing between Incompatible Oils
521
Filling in Oil
522
Topping up with Oil
522
Change the Roller Bearing Grease
523
Service Life of the Lubricants
523
Recommended Lubricants
525
Replace Bearings
526
Checking the Gearbox for Leaks
527
Replacing the Vent Valve
527
Checking the Oil Level Sensor (Optional)
527
Checking the Tightness of Fastening Bolts
528
Replacing the Hose of the Oil Expansion Unit
528
Mounting Positions
529
General Notes on Mounting Positions
529
Single-Stage Helical Gearboxes
530
Two- and Three-Stage Helical Gearbox
532
Parallel Shaft Gearbox
539
Bevel Gearbox
545
Helical Worm Gearbox
554
Oil Quantities
563
Helical Gearbox
563
Parallel Shaft Gearbox
564
Bevel Gearbox
565
Helical Worm Gearbox
566
Replacement Part Lists Gearbox
567
Helical Gearbox E, Sizes 39 - 89
567
Helical Gearbox D / Z, Sizes 19 - 89
568
Parallel Shaft Gearbox F, Sizes 29 - 89
570
Bevel Gearbox B, Sizes 19 - 49
572
Bevel Gearbox K, Frame Sizes 39 - 109
575
Helical Worm Gearbox C, Sizes 29 - 89
577
SIMOLOC Assembly System, Sizes 29 - 89
580
Appendix
583
Interconnecting Signals in the Converter
583
Fundamentals
583
Application Example
585
Acceptance Tests for the Safety Functions
586
Recommended Acceptance Test
586
Acceptance Test STO (Basic Functions)
587
Machine Documentation
588
Manuals and Technical Support
590
Overview of the Manuals
590
Configuring Support
591
Product Support
592
Index
595
4
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Siemens SINAMICS G115D Specifications
General
Brand
Siemens
Model
SINAMICS G115D
Category
DC Drives
Language
English
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