Learning targets ...............................................................................................................................

2
Principle of a frequency inverter ....................................................................................................... 3
Power Module Overview ................................................................................................................. 5
Power Module Cable Lengths ........................................................................................................... 7
Power Module PM230 ...................................................................................................................... 8
Power Module PM240-2 ................................................................................................................... 9
Power Module PM250 ...................................................................................................................... 10
SINAMICS G120C .......................................................................................................................... 11
SINAMICS G120D .......................................................................................................................... 12
SINAMICS G120X ............................................................................................................................ 13
Electromagnetic compatibility ........................................................................................................... 14
Notes on installation ......................................................................................................................... 16
Intelligent Operator Panel IOP-2 ....................................................................................................... 18
Smart Access Module SAM .............................................................................................................. 22
Exercises ......................................................................................................................................... 24
Exercise 1: Commissioning with the IOP-2 ....................................................................................... 25
Exercise 2: Operation with the IOP-2 ................................................................................................ 28
Exercise 3: Factory settings with the IOP-2 ...................................................................................... 29
...................................................................................... 30

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Training Document 2-1 Power Module and Operator Panel IOP-2
SITRAIN Page Course DR-G12-PM
Training Document 2-2 Power Module and Operator Panel IOP-2
Mode of operation In a rectifier circuit the three-phase current from the power supply is rectified.
This results in a DC voltage, which is buffered by capacitors (DC link).
A power section with transistors takes this DC voltage and generates a three-
phase current with a variable frequency and voltage from it.

V/f characteristic Variable voltage? The motor primarily represents an inductive resistance for the
current flow. When the frequency increases, so does the inductive resistance.
The inverter must therefore increase the output voltage in proportion to the
output frequency. This relationship is referred to as the V/f characteristic.

Transistors (IGBTs) Insulated Gate Bipolar Transistors are used as semiconductor switches in the
inverter.

Free-wheeling diodes As the motor represents inductive resistance, the current flow is smoothed.
To enable the current to continue to flow when the transistors pause, there is
one built-in diode for each transistor.

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

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Training Document 2-3 Power Module and Operator Panel IOP-2
Switching frequency The DC link voltage is switched on and off in order to produce the variable
voltage at the inverter's output.
A fixed switching frequency (pulse frequency) of a few kHz is employed.
Pulse-width
modulation The mean value of the output voltage is the crucial factor. This value is varied
as a function of the switch-on/switch-off timing. Therefore, the width of the
pulses changes at a constant switching frequency (pulse-width modulation -
PWM).

Sine-wave A sinusoidal mean voltage value can be generated by continuously varying the
pulse-width modulation. This is the fundamental frequency of the three-phase
current.

Three-phase current If all 6 transistors are triggered in a particular combination, a three-phase

current with a frequency between 0 Hz and 650 Hz is generated (depending on
the particular inverter type and control variant).

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Training Document 2-4 Power Module and Operator Panel IOP-2
PM230 PM230 was specifically designed for drives of pumps, fans and compressors.
Available in IP20 and IP54/55 degrees of protection,
it is optimally suited for building engineering.
Due to the special design with a mains-friendly DC link, no line reactor is
needed. This saves space and weight, and reduces power dissipation.

PM240-2 PM240-2 implements the principle of a DC link converter that has been used for
decades. It is also suitable for highly dynamic applications with rapid load
changes. It also controls regenerative operation with braking resistor.
In another design, such power units can be connected together in the DC link to
create a multi-motor system for the SINAMICS S120 converter series.
The new hardware platform (-2) enables higher power density as well as
innovative cooling concepts with push-through technology (PT-technology).

PM250 If load changes and regenerative operation occur, the PM250 is the innovative
solution. 4-quadrant operation and regenerative feedback is allowed. A typical
area of application is conveyor technology.

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Training Document 2-5 Power Module and Operator Panel IOP-2
IP20PT PT is the abbreviation for “Push Through“, an innovative cooling principle for the
use in cabinets. The heat losses are emitted directly to the outside.

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Training Document 2-6 Power Module and Operator Panel IOP-2
SITRAIN Page Course DR-G12-PM
Training Document 2-7 Power Module and Operator Panel IOP-2
PM230 PM230 was specifically designed for drives of pumps, fans and compressors.
Available in IP20 and IP54/55 degrees of protection,
it is optimally suited for building engineering.
Due to the special design with a mains-friendly DC link, no line reactor is
needed. This saves space and weight, and reduces power dissipation.

PT Push Through, installation with through-hole technology in which the heat sink
extends to back out of the cabinet.

LO Performance data with low overload (LO)

HO Performance data with high overload (HO)

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Training Document 2-8 Power Module and Operator Panel IOP-2
PM240-2 The new PM240-2 Power Modules are based on a new hardware platform. This
permits an increase in power density as well as the application of innovative
cooling concepts (push-through technology) with especially high requirements in
terms of control cabinet cooling.

Furthermore, the PM240-2 Power Module is also suitable for use in safety-
oriented applications. In conjunction with a fail-safe Control Unit, the drive can
be transformed into a Safety Integrated Drive.

The PM240-2 Power Modules are available up to 90 kW both with and without
an integrated line filter class A of compact design for 200 V and 400 V line
voltages.

The PM240-2 Power Modules with integrated line filter class A are suitable for
connection to TN supply systems. Power Modules without integrated line filter
can be connected to grounded TN/TT systems and non-grounded IT systems.

LO Performance data with low overload (LO)

HO Performance data with high overload (HO)

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Training Document 2-9 Power Module and Operator Panel IOP-2
PM250 PM250 Power Modules are suitable for many applications in general machinery
construction. Any braking energy is directly fed back into the line supply (four
quadrant applications – a braking chopper is not required).

The PM250 Power Module features an absolutely unique technology – Efficient

Infeed Technology. This feature provides the ability to feed energy back into the
supply system in the generator mode (electronic braking) so that the energy is
not wasted in a braking resistor. This saves space in the control cabinet. The
time-consuming process of dimensioning the braking resistor and the expense
of the extra wiring are eliminated. Furthermore, heat losses in the control
cabinet are reduced.

Further, the innovative circuit design reduces the line harmonics. There is no
need to use an optional line reactor at the supply infeed. This saves space and
costs for engineering and procurement.

The PM250 Power Modules with integrated line filter class A are suitable for
connection to TN supply systems. Power Modules without integrated line filter
can be connected to grounded TN/TT systems and non-grounded IT systems.

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Training Document 2 - 10 Power Module and Operator Panel IOP-2
G120C The SINAMICS G120C compact converter offers a balanced mix of features for
a wide variety of applications. The SINAMICS G120C is a compact, robust and
easy-to-use converter and can optionally be equipped with a simple or
convenient operator panel.
SINAMICS G120C is specifically designed for the requirements of system
integrators, OEMs and distributors to provide high productivity and tailored
performance.

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Training Document 2 - 11 Power Module and Operator Panel IOP-2
G120D The SINAMICS G120D distributed frequency converter is the solution for
demanding drive tasks especially in the area of conveyor technology.
SINAMICS G120D enables stepless speed control of AC induction motors and
meets all the requirements of material handling applications from simple
frequency control to sophisticated vector control.

IP65 With its sophisticated modular design with IP65 degree of protection, it fits
seamlessly into the system while enabling high system availability combined
with low stocking of spare parts. The innovative recovery power unit concept
helps to save energy.
The patented realization concept of integrated safety functions is unique
throughout the world and enables improved plant designs with higher
productivity. This drive can be seamlessly integrated into the Siemens TIA world
of automation by means of PROFIBUS or PROFINET.

Power range With it various device models (sizes FSA to FSC) in the power range from 0.75
kW to 7.5 kW, it is suitable for a variety of drive solutions.

CU240D-2 The CUs have been expanded in I/0 scaling. The safety function STO ("Safe
Torque Off") is integrated in all variants of the SINAMICS control units. The
safety functions (SLS, SS1) and SDI (Safe Direction) and SSM (Safe Speed
Monitoring) are supported in the failsafe design.

CU250D-2 The CU250D-2 can now implement applications with positioning requirements
in the drive. This enhancement now allows use in hoisting/traverse/travel or
rotary applications.
• Vector (VC) and sensorless vector control (SLVC) is possible
• Positioning by means of an encoder (HTL/SSI) or
parallel with two sensors (HTL and SSI)

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Training Document 2 - 12 Power Module and Operator Panel IOP-2
G120X SINAMICS G120X is optimized for infrastructure and industrial
water/wastewater applications as well as pumps and fans in building
automation.
This makes SINAMICS G120X the first choice for users who want to tap on the
power of the elements to improve the quality of people’s lives.
Part of a complete and seamless family of products, the frequency converter
meets practically every requirement.

The frequency converter comes as a complete product series – standardized

and seamless when it comes to all supply voltages and supply types, and
available in a power range extending from 0.75 kW to 630 kW. The devices are
in compliance with global EMC standards and motor cable lengths of up to 150
m are permissible while maintaining EMC limit values. The integrated Safe
Torque Off (STO) safety function is certified according to SIL3.
Thanks to its rugged design with optional protection against dripping water,
SINAMICS G120X can be used in harsh conditions.
The frequency converter can also be operated under environmental conditions
according to the 3C3 standard.
Thanks to its connection to the Cloud with SINAMICS CONNECT 300,
SINAMICS G120X also readies your drive application for digitalization.

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Training Document 2 - 13 Power Module and Operator Panel IOP-2
EMC Electromagnetic compatibility refers to the state in which there is no mutual
interference between technical devices caused by unintentional electrical or
electromagnetic effects.

Line side The rapid switching operations in pulse-width modulation with a sharp increase
in voltage produce effects on the power supply via the DC link and the rectifier.
An EMC filter is always integrated as a counter-measure.
The current harmonics from rectifier circuits contribute to the overall harmonic
load on the power supply. The line-friendly DC link keeps the share of the
PM230 very low.

Motor side Here, too, rapid switching operations in pulse-width modulation present a
potential source of interference. Shielded cables, whose shields are applied to
the inverter and motor with the greatest possible surface area prevent EMC
interference.

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Training Document 2 - 14 Power Module and Operator Panel IOP-2
Classification For economic and practical reasons, the power supplies are classified with
regard to their limit values in two environments:
• Residential area = First environment
• Industrial network = Second environment

Line connection The differentiation is made on the basis of the line connection:
• In the first environment, residential buildings, public buildings and
commercial premises are all connected to a low-voltage network.
Interference can spread directly to neighboring buildings.
• Large industrial plants are supplied by a medium-voltage network via a
separate transformer. The transformer reduces the spread of interference,
so interference suppression in industrial networks can be achieved in
accordance with higher limit values.

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Training Document 2 - 15 Power Module and Operator Panel IOP-2
Application Earth leakage circuit breaker (ELCB) are used to detect currents that do not
flow back in the cables but find a different path to ground. A defect may be the
cause and, in the worst case, the current can flow through a person's body.
This is why ELCBs are often used in residential and office premises (often
stipulated as mandatory).

Inverter operation Three-phase current systems have the following problems when inverters are
used:
• Leakage currents flow to ground via the EMC filter; the ELCB interprets
these as faults and trips.
• A fault in the DC link of the inverter can cause summation DC current to
flow, which can magnetize the ELCB and adversely affect its operation.
This is why three-phase inverters are not operated using ELCBs.
Sensitive to
universal current If operation with an ELCB is nevertheless requested, an ELCB that is sensitive
to universal current can be used; it can, however, be quite expensive.

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Training Document 2 - 16 Power Module and Operator Panel IOP-2
Cable shield The general rules for application and contact of the braided shield apply:
• Ground the shields at both ends over a large contact area
• Attach shield immediately after cabinet entry point; continue cable run with
shielded cable
• Plug-in connections of shielded cables via metallic connector housings
Equipotential
bonding Good potential equalization between all components is a further prerequisite for
good electromagnetic compatibility:
• potential equalization between plant components with adequately
dimensioned cross-section (> 10 mm², 16 mm² recommended)
• Connect potential compensation cables to central grounding bar

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Training Document 2 - 17 Power Module and Operator Panel IOP-2
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Training Document 2 - 18 Power Module and Operator Panel IOP-2
Menu “Setup” The IOP-2 Setups are question-driven environment that assist the user to set-up
various functions and applications of the converter.

Menu “Parameters” The parameter menu allows the user extensive functionality and access to all
the converter parameters.

Menu “Control” The Control menu allows the user to control the drive and to change the drive
settings in real-time.

Menu “Diagnostics” Here you can access all relevant diagnostics functions.

Menu “Menu” The “Menu” screen displays all menu options in detail.
The functions “Up-/Download” and “Extras” can be accessed her additionally.

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Training Document 2 - 19 Power Module and Operator Panel IOP-2
Note Further information is provided in the "Operating Instructions SINAMICS
IOP-2“. Make sure you have the current firmware version.

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Training Document 2 - 20 Power Module and Operator Panel IOP-2
Menu “Extras” The Extras menu presents a number of options for the configuration of
the IOP-2
• The “Status Screen Wizard” allows the user to configure the information
displayed on the status screen. By default it displays output voltage and
output frequency of the converter.
• The “I/O Editor” allows the user to configure the digital and analog inputs and
outputs of the converter.
• The “Drive Identity” option allows the user to display the technical details of
the components that comprise the converter system.
• With the “Parameter Settings” you can reset the drive to the factory settings
or change and save the drive settings.
• The “Panel Settings” allows the user to change the panel language and other
settings, e.g. the display backlight.

Note Further information is provided in the " Operating Instructions SINAMICS

IOP-2“. Make sure you have the current firmware version.

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Training Document 2 - 21 Power Module and Operator Panel IOP-2
Secure connection You can establish a SSL secure connection (https://) if needed.
To access the SINAMICS G120 Web pages with https:// from a Windows 10-
based PC or iOS-based mobile devices, you need to install SSL certificates.
For further information please refer to the SAM operating instructions.

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Training Document 2 - 22 Power Module and Operator Panel IOP-2
Note SINAMICS G120 Smart Access is only for commissioning and thus cannot be
used with the inverter permanently.

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Training Document 2 - 23 Power Module and Operator Panel IOP-2
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Training Document 2 - 24 Power Module and Operator Panel IOP-2
Requirements G120 training case with CU2x0x-2 (as of FW4.7.10) and IOP-2 (as of FW
2.3.1).

Task Perform basic commissioning for a conveyor drive using the IOP-2.
Use the “Quick Startup” to commission the drive.
Use the CU inputs as command and setpoint sources. To do so, follow the
steps described below.
Note Please note how the induction motor of your train training device is connected,
either for 230 or 400 V.
If necessary, ask your course instructor.

1. Select “Setup" and click OK.

2. Select "Quick Startup".
3. The 1st step "factory Reset" allows you to restore the parameters to their
factory settings (in every wizard). Select "Yes" and confirm by pressing the
OK key.

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Training Document 2 - 25 Power Module and Operator Panel IOP-2
 4. Progress through the following screen to enter the motor data according to
the rating plate of the induction motor.
Leave min. speed setting at 0 rpm and max. speed at 1.500 rpm.
5. Set the ramp-up and ramp-down times to 5 seconds in each case.
6. In the I/O Setup select the macro “(12) Standard I/Os with analog setpoint”.
7. You can subsequently check all your settings again in the overview.

Note Command sources are selected on the IOP-2 by means of a macro number
entered in parameter p15 as well as the plain text selection described in the
manual or by the macro name.
If the text is longer than the with of the IOP-2 they are displayed as running text.
You will find a detailed description of all available macros in the Operating
Instructions, Chapter 4.6 “Installing Control Unit".

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Training Document 2 - 26 Power Module and Operator Panel IOP-2
 7. Complete the quick setup by pressing “OK” and confirm “Safe Settings?”.
8. When the setup is saved a message will appear stating that the motor data
ID run will be performed when the unit is switched on.
This will be performed in exercise 2.

Note The motor data ID run in standstill is automatically activated with this quick
setup and will be performed when the unit is switched on.
You can recognize this as well as the alarm A07991 (“MotID activated”) is
displayed.
You can deactivate this by changing parameter p340, using the “Advanced
Setup” or in Startdrive.

WARNING! Motor data identification with hazardous loads!

Before you start the motor identification run, you must secure any hazardous
plant sections by cordoning off the danger zone, for example, or by lowering a
suspended load onto the ground.
If in doubt, omit rotational measurement and perform only motor data
identification at standstill!

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Training Document 2 - 27 Power Module and Operator Panel IOP-2
Task You have now finished parameterizing the inverter, but it is not yet ready for
operation. You now need to start the motor data identification routine.
You now need to start the inverter in order to perform the motor data
identification. To do this, carry out the steps described below:
1. Using the "MANUAL/AUTO" key, switch to the MANUAL operating mode
("HAND" symbol appears in the status display).
2. Switch on the inverter by pressing the "I" key and wait until the measurement
is complete.
3. Using the "MANUAL/AUTO" key, switch to the AUTO operating mode again
("AUTO" symbol appears in the status display).
The inverter is now ready to operate.

Test the functions In step 6 of ecercise 1 you selected "Standard I/Os with analog setpoint" (this
corresponds to macro no. 12). With this selection, the command and setpoint
sources in the CU were connected as specified below:
• Switch DIN0 (DI0) ON/OFF 1 On/Off switch
• Switch DIN0 (DI1) Reversing Reverse direction of rotation
• Switch DIN0 (DI2) Acknowledge Faults can be acknowledged
• Lamp RL1 (DO0) Fault One/several faults pending
• Lamp RL2 (DO1) Alarm One/several alarms pending
• Lamp RL3 (DO2) Operation Inverter is running
• Pot. ADC0 (AI0) Setpoint Speed setpoint setting
Test these connections and monitor the display on the IOP-2.

Note You will find a detailed description of all available macros in the Operating
Instructions, Chapter 4.6 “Installing Control Unit".

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Training Document 2 - 28 Power Module and Operator Panel IOP-2
Requirements G120 training case with CU2x0x-2 (as of FW4.7.6) and IOP-2 (as of FW 2.0.1).
Disabled safety functions if the Control Unit has safety functions.

Task In order to create a starting point for continuing commissioning with the IOP-2,
you should restore the factory settings on the G120.
Restoring the factory settings using the IOP-2:

1. Select "Menu" and click OK.

2. Select “EXTRAS" and confirm with OK.
3. Select “parameter settings" and confirm with OK.
4. Select "drive factory reset".
5. Acknowledge the prompt with "yes".
6. The IOP-2 will display "in progressQ please wait" for several seconds and
then finally "Factory reset completed successfully“.
The factory settings have now been restored on the inverter.

Note Every IOP-2 wizard features an option which allows you to restore factory
settings. You are advised to make use of this option when you are working with
the wizard.
Then you will not need to carry out the above steps separately.
When you restore the inverter to its factory settings, the bus address and baud
rate remain unchanged.

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Training Document 2 - 29 Power Module and Operator Panel IOP-2
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Training Document 2 - 30 Power Module and Operator Panel IOP-2