Siemens SINAMICS G115D

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Corrective maintenance

10.7Reduced acceptance test after component replacement and 󹪝rmware change

SINAMICS G115D Wall Mounted distributed drive

410 Operating Instructions, 07/2023, FW V4.7 SP14, A5E52808211A AA

Main Page

Preface5
Table of Contents7
Changes in the Manual17
Fundamental Safety Instructions19
General Safety Instructions19
Equipment Damage Due to Electric Fields or Electrostatic Discharge25
Warranty and Liability for Application Examples25
Cybersecurity Information25
Residual Risks of Power Drive Systems27
Overview of the SINAMICS G115D Drive29
System Overview29
Scope of Delivery30
SINAMICS G115D Wall Mounted30
Directives and Standards35
Optional Components36
External Braking Resistor36
Connectors37
Glanded Installation Kit38
Connector Cover Kit38
SINAMICS G120 Smart Access39
SAM Interface Kit39
Mounting41
Mounting the G115D Wall Mounted Drive41
Mounting the Optional Components44
Mounting the External Braking Resistor44
Mounting the SINAMICS G120 Smart Access46
Wiring51
EMC Installation Guidelines51
Connections and Interference Suppression51
Basic EMC Rules51
Equipotential Bonding52
Permissible Line Supplies54
TN Line System55
TT Line System55
Line System56
Requirements for the Protective Conductor59
Requirements for Branch Circuit Protection60
Operation with Residual Current Protective Device (RCD)60
Forming DC Link Capacitors61
Overview of the Converter Interfaces62
Overview62
Cables and Connectors66
Maximum Permissible Cable Length67
Cable Cross-Sections and Cable Lugs68
Connecting the Line Supply71
Interface Description - X1/X371
Connecting to the Line Supply Using Daisy Chain73
Connecting the Motor75
Interface Description - X276
Connecting the Motor in a Star or Delta Connection77
Overview77
Configuring the Star/Delta Connection of the Wall-Mounted Converter79
Connecting the 24 V Power Supply79
Interface Description - X01/X0279
Connecting to the 24 V Power Supply Using Daisy Chain81
Connecting the Digital Inputs and Outputs83
Interface Description - X07/X08/X0583
Factory Interface Setting84
Fail-Safe Digital Input90
Connecting to PROFINET and Ethernet91
Interface Description - X150 P1/P291
Communication Via PROFINET IO and Ethernet91
Protocols Used92
Connecting the Converter to PROFINET94
What Do You Have to Set for Communication Via PROFINET94
Installing GSDML95
Connecting the Converter to Ethernet/Ip96
What Do You Need for Communication Via Ethernet/Ip96
Connecting to AS-I97
General Information97
Interface Description - X0398
Setting the Address98
Using the AS-I Programmer100
Connecting to SINAMICS G115D I/O Variant102
Grounding the Converter Housing102
Connecting the External Braking Resistor103
Connection Examples105
Commissioning107
Commissioning Guidelines107
Commissioning Tools108
Preparing for Commissioning109
Factory Settings109
Collecting Motor Data111
Selecting U/F Control or Speed Control113
Calculating Maximum Speed for Permanent Magnet Synchronous Motors114
Quick Commissioning115
Quick Commissioning with DIP Switches115
Quick Commissioning with a PC (Startdrive)118
Creating a Project119
Integrating the Converter into the Project119
Starting the Commissioning Wizard121
Carrying out Quick Commissioning121
Identifying Motor Data123
Quick Commissioning with the SINAMICS G120 Smart Access125
Self-Optimization of the Speed Control126
Saving the Settings in the Converter (RAM → EEPROM)126
Restoring the Factory Settings127
Restoring the Factory Settings/Delivery Condition (Without Safety Functions)128
Resetting the Safety Functions to the Factory Settings129
Advanced Commissioning131
Overview of Converter Functions131
Sequence Control When Switching the Motor on and off133
Adapt the Default Settings of the Inputs and Outputs135
Overview135
Digital Inputs136
Digital Outputs137
Controlling Clockwise and Counter-Clockwise Rotation Via Digital Inputs138
Two-Wire Control, Method 1139
Two-Wire Control, Method 2140
Two-Wire Control, Method 3141
Three-Wire Control, Method 1142
Three-Wire Control, Method 2143
Drive Control Via PROFINET144
Receive Data and Send Data144
Telegrams145
Control and Status Word 1147
Control and Status Word 3149
Control and Status Word G115D150
NAMUR Message Word152
Parameter Channel152
Expanding or Freely Interconnecting Telegrams156
Acyclically Reading and Writing Converter Parameters158
Drive Control Via Ethernet/Ip159
Configuring Communication Via Ethernet/Ip159
Supported Objects162
Supported ODVA AC/DC Assemblies173
Creating Generic I/O Module174
The Converter as Ethernet Node175
Drive Control Via AS-I175
Single Slave Mode175
Dual Slave Mode177
Assignment Tables180
Cyclic and Acyclic Communication Via CTT2182
Cyclic Communication183
Acyclic Communication - Standard184
Acyclic Communication - Manufacturer-Specific184
Jogging186
Conveyor Technology Control Functions (for G115D PROFINET and AS-I Variants Only)187
Conveyors188
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
Turntables196
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 Lifts210
Corner Turntable Lift, Two Positions and One Speed (P3393 = 9)211
Corner Turntable Lift, Two Positions and Two Speeds (P3393 = 10)214
Travelling Trolleys216
Travelling Trolley, One Speed (P3393 = 11)217
Travelling Trolley, Two Speeds (P3393 = 12)219
Conveyor Technology Control Parameters222
Switching over the Drive Control (Command Data Set)224
7.11 Motor Holding Brake226
Encoder Interface231
Free Function Block232
Selecting Physical Units232
Motor Standard232
System of Units233
Technological Unit of the Technology Controller234
Setting the System of Units and Technology Unit235
Safe Torque off (STO) Safety Function235
Function Description236
Commissioning STO238
Commissioning Tool238
Safety Function Password238
Configuring a Safety Function239
Interconnecting the "STO Active" Signal240
Setting the Filter for Fail-Safe Digital Inputs241
Setting the Forced Checking Procedure (Test Stop)244
Finalizing Online Commissioning245
Checking the Interconnection of Digital Inputs247
Acceptance - Completion of Commissioning248
Safely Limited Speed (SLS)249
Setpoints257
Overview257
Specifying the Setpoint Via the Fieldbus258
Electromechanical Potentiometer259
Motorized Potentiometer as Setpoint Source260
Fixed Speed Setpoint as Setpoint Source264
Setpoint Processing267
Overview267
Invert Setpoint268
Inhibit Direction of Rotation269
Skip Frequency Bands and Minimum Speed270
Speed Limitation271
Ramp-Function Generator272
PID Technology Controller277
Motor Control284
Setting the Saturation Characteristic of the Permanent Magnet Synchronous Motor (Third-Party Motor)284
U/F Control286
Characteristics of U/F Control287
Selecting the U/F Characteristic288
Optimizing Motor Starting289
Sensorless Vector Control with Speed Controller291
Structure of Vector Control Without Encoder (Sensorless)291
Optimizing the Closed-Loop Speed Controller293
Advanced Settings295
Optimizing the Operation of the Permanent Magnet Synchronous Motor297
Friction Characteristic299
Moment of Inertia Estimator301
Pole Position Identification308
Torque Control310
Electrically Braking the Motor311
DC Braking312
Dynamic Braking315
Overcurrent Protection317
Converter Protection Using Temperature Monitoring318
Motor Temperature Monitoring Using a Temperature Sensor322
Motor Protection by Calculating the Temperature325
Motor and Converter Protection by Limiting the Voltage327
Monitoring the Driven Load329
Load Monitoring329
Rotation Monitoring330
Torque Monitoring331
Blocking Protection, Leakage Protection and Dry-Running Protection333
7.28 Efficiency Optimization336
Calculating the Energy Saving for Fluid Flow Machines339
Switchover between Different Settings342
Activating Licensed Functions344
Licensing344
Creating or Displaying the License Key345
Writing the License Key to the Card347
Recommended Memory Cards349
Data Backup and Series Commissioning353
Transferring Settings Using a Memory Card354
Memory Cards354
Converter → Memory Card355
Memory Card → Converter357
Activating Message for a Memory Card that Is Not Inserted359
Transferring Settings Using a PG/PC360
Converter → PG/PC360
PG/PC → Converter361
Other Ways to Back up Settings363
Write Protection363
Know-How Protection364
Extending the Exception List for Know-How Protection366
Activating and Deactivating Know-How Protection368
Alarms, Faults and System Messages371
Status LED Overview371
System Runtime375
Identification & Maintenance Data (I&M)375
Alarms, Alarm Buffer, and Alarm History376
Faults, Fault Buffer and Fault History380
List of Alarms and Faults383
Corrective Maintenance389
Spare Parts Compatibility389
Replacing the Converter390
Replacing the Converter Hardware390
Replacing a Converter with Active Know-How Protection392
Replacing a Converter with Know-How Protection Without Copy Protection392
Replacing a Converter with Know-How Protection with Copy Protection392
Replacing the Spare Parts394
Spare Parts Overview395
Replacing the Electronic Module396
Replacing the Fan Unit398
Repair Switch400
Local/Remote Control Panel401
Firmware Upgrade and Downgrade403
Preparing the Memory Card405
Upgrading the Firmware405
Downgrading the Firmware408
Correcting an Unsuccessful Firmware Upgrade or Downgrade410
Reduced Acceptance Test after Component Replacement and Firmware Change411
Technical Data413
Technical Data of the G115D Wall-Mounted Converter413
General Converter Technical Data413
Technical Data of Inputs and Outputs415
Technical Data Dependent Upon the Power415
Technical Data of Braking Resistors417
Load Cycles and Overload Capabilities419
Derating Data420
Torque Derating as a Function of the Installation Altitude420
Current Derating as a Function of the Surrounding Temperature421
Torque Derating as a Function of the Line Voltage421
Current Derating as a Function of the Pulse Frequency422
Derating of Motor Cable Length Based on Pulse Frequency and Surrounding Temperature423
Low Frequency Operation423
Data Regarding the Power Loss in Partial Load Operation424
Electromagnetic Compatibility of the Converter424
Protecting Persons from Electromagnetic Fields426
Additional Information on the SIMOGEAR Geared Motor429
General Information Geared Motor with SINAMICS G115D Motor Mounted / Wall Mounted429
Specific Hazard Types and Fundamental Obligations429
Rating Plate430
Surface Treatment430
General Information on Surface Treatment430
Painted Version431
Primed Version433
Incoming Goods433
General Information on Transport434
Unpacking435
General Information Concerning the Installation435
Installation Notes437
Thread Sizes and Tightening Torques for Fastening Bolts438
Operation439
Cleaning the Geared Motor439
Inspecting the Geared Motor440
Disposal440
Technical Data441
Type Designation Motor and Converter441
Gearbox Type Designation442
General Technical Data443
Rating Plate for Geared Motors with SINAMICS G115D Motor Mounted444
Rating Plate for Geared Motors with SINAMICS G115D Wall Mounted445
Weight446
Sound Energy Level446
Spare Parts447
Stocking of Spare Parts447
Spares on Web448
Specific Data Motor449
General Motor Information449
Use as Prescribed449
General Technical Description450
Cooling451
Terminal Box and Application Box451
Fastening for Suspended Transport452
Storage452
Installation Conditions for the Motor453
Condensation Drain Hole (Optional)454
Connecting the Motor in the Terminal Box454
General Notes for Motor Connection (Wall Mounted)455
Terminal Box456
Terminal Marking457
Direction of Rotation457
Connecting the Cables in the Terminal Box458
External Grounding459
Mounting and Installation (Wall Mounted)459
Converter Operation461
Checking the Insulation Resistance (Wall Mounted)462
Commissioning the Motor463
Faults, Causes and Remedies465
General Notes about Maintenance466
Locking the Manual Release of the Brake (Optional)467
Lubrication467
Checking the Tightness of Fastening Bolts469
Inspection of the Motor469
Servicing the Brake469
Wear of the Spring-Operated Brake469
Maintenance Intervals for the Brake470
Adjusting the Air Gap471
Replacing the Friction Lining473
Circuit Diagrams474
Spare Parts List, Motor476
Motor Frame Sizes 71 - 132476
Brake480
Specific Data Gearbox481
General Information Gearbox481
Use for the Intended Purpose482
General Technical Description482
Shaft Seals483
Cooling484
Fastening for Suspended Transport485
Storage486
General Information for Storage486
General Notes for Storage up to 36 Months487
Gearbox Filled with Operating Oil and Anti-Corrosive Agent487
Gearbox Completely Filled with Oil487
Gearbox with Foot Mounting488
Gearbox with Flange Mounting488
Gearboxes in Foot or Flange Version489
Mounting an Input or Output Element on the Gearbox Shaft490
Removing and Installing the Protection Cover492
General Information on Installing the Shaft-Mounted Gearbox493
Hollow Shaft with Feather Key494
Mounting the Hollow Shaft with Parallel Key494
Removing the Hollow Shaft with Parallel Key495
Hollow Shaft with Shrink Disk497
Mounting the Hollow Shaft with Shrink Disk497
Mounting the Shrink Disk498
Pulling off the Shrink Disk500
Cleaning and Lubricating Shrink Disks500
SIMOLOC Assembly System501
General Notes for the SIMOLOC Assembly System501
Installing SIMOLOC503
Removing SIMOLOC505
Hollow Shaft with Splines506
Torque Arms with Slip-On Gearboxes507
General Information Regarding Torque Arms507
Mounting Torque Arms on Parallel Shaft Gearboxes507
Mounting Torque Arms on Bevel Gearboxes and Helical Worm Gearboxes508
General Information about Commissioning509
Checking the Oil Level Prior to Commissioning510
Mounting the Oil Expansion Tank510
Faults, Causes and Remedies512
General Notes about Maintenance Work514
Checking and Changing Lubricants516
General Safety Instructions516
Checking the Oil Level517
Checking the Oil Level Using the Oil Sight Glass (Optional)518
Checking the Oil Level Using the Oil Dipstick (Optional)518
Checking the Oil Quality519
General Safety Notes for Changing the Oil520
Draining the Oil520
Flushing the Gearbox When Changing between Incompatible Oils521
Filling in Oil522
Topping up with Oil522
Change the Roller Bearing Grease523
Service Life of the Lubricants523
Recommended Lubricants525
Replace Bearings526
Checking the Gearbox for Leaks527
Replacing the Vent Valve527
Checking the Oil Level Sensor (Optional)527
Checking the Tightness of Fastening Bolts528
Replacing the Hose of the Oil Expansion Unit528
Mounting Positions529
General Notes on Mounting Positions529
Single-Stage Helical Gearboxes530
Two- and Three-Stage Helical Gearbox532
Parallel Shaft Gearbox539
Bevel Gearbox545
Helical Worm Gearbox554
Oil Quantities563
Helical Gearbox563
Parallel Shaft Gearbox564
Bevel Gearbox565
Helical Worm Gearbox566
Replacement Part Lists Gearbox567
Helical Gearbox E, Sizes 39 - 89567
Helical Gearbox D / Z, Sizes 19 - 89568
Parallel Shaft Gearbox F, Sizes 29 - 89570
Bevel Gearbox B, Sizes 19 - 49572
Bevel Gearbox K, Frame Sizes 39 - 109575
Helical Worm Gearbox C, Sizes 29 - 89577
SIMOLOC Assembly System, Sizes 29 - 89580
Appendix583
Interconnecting Signals in the Converter583
Fundamentals583
Application Example585
Acceptance Tests for the Safety Functions586
Recommended Acceptance Test586
Acceptance Test STO (Basic Functions)587
Machine Documentation588
Manuals and Technical Support590
Overview of the Manuals590
Configuring Support591
Product Support592
Index595

Siemens SINAMICS G115D

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