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.
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
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
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
1.1
Control mode Safety functions used with encoder ? no None or externally implemented
Energy recovery
ICU24
By using the integrated safety functions with encoder, it is possible that external safety relays and contactors can be eliminated
Profibus
with Extended Additional safety functions Safety license without encoder are STO / SS1 / SLS / available SDI / SSM / SBC
no ICU24 yes
no yes no
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
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 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.
2 Hardware
2.1.2
SINAMICS G120
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).
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)
6 up to 1
3.1.1
3.1.1.1
3.1.2
3 IO interface
3.1.3
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
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
10
3 IO interface
3.3.1
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
3.5
11
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
4.2
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
X X X
X X
X X
X X
12
4 Communication
4.4
Presently, the following systems do not support data set routing: SIMATIC S7-1200 WinAC MP SIMOTION
13
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.
14
4 Communication
4.5.2
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).
15
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
5.1.3
5.1.4
16
5 Parameterization
5.1.5
5.1.6
5.1.7
5.1.8
5.1.9
5.1.10
17
5 Parameterization
5.2
5.2.1
5.2.2
5.2.3
5.2.4
5.2.5
18
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.
19
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):
no
yes
no
yes
no
yes
no
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.
20
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
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.
21
6 Safety functions
6.1.2
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.
22
6 Safety functions
6.1.3
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
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.
23
6 Safety functions
6.2
6.2.1
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.
24
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.
25
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 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))
26
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
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.
27
6 Safety functions
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
6.7
28
7
7.1
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
29
30