06 Control Signals and Signal Interconnections en

Learning targets ...............................................................................................................................
2
Control signal source ....................................................................................................................... 3
Control word 1 ................................................................................................................................. 4
Control word 2 ................................................................................................................................. 7
Status word 1 ................................................................................................................................... 8
Status word 2 ................................................................................................................................... 9
Diagnostics in Startdrive ................................................................................................................... 10
Signal interconnections .................................................................................................................... 11
Free blocks ...................................................................................................................................... 15
Function block diagrams .................................................................................................................. 20
Exercises ......................................................................................................................................... 21
Exercise 1: Control word .................................................................................................................. 22
Exercise 2: Status word ................................................................................................................... 24
Exercise 3: Diagnostics with Startdrive ............................................................................................. 26
Exercise 4: Error memory ................................................................................................................. 27
Exercise 5: Free blocks .................................................................................................................... 29
Exercise 6: Trace ............................................................................................................................. 31
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Training Document 6-1 Control signals and Signal interconnections
I/O configuration You can select the I/O configuration by using the configuration wizard or directly
via the parameter p0015. The I/O configuration is preassigned with automatic
macros, so not further action is required.
You may find detailed information about these preassigned configurations in the
user manual of the specific control unit.

Control word 1 The control word 1 is a group of 16 internal binary signals for controlling the
inverter.
Command data set

(CDS) Using the command data sets (CDS) you can set the inverter control in various
ways and toggle between the settings. For instance the inverter can either be
operated via a fieldbus or via the terminal strip.
The settings in the inverter, which are associated with a certain control type of
the inverter, are known as a command data set.
Example:
• Command data set 0: Controlling the inverter via the fieldbus
• Command data set 1: Controlling the inverter via terminal strip

PROFIdrive For a digital drive coupling, the Drive Technology profile provides the following
stop modes:
• Control word 1 bit 0 = 0 (OFF1): Stop with ramp.
The drive travels with a speed ramp with adjustable deceleration to
zero speed. The stopping process can be interrupted and the drive
reactivated. After stopping, a pulse suppression is carried out and the status
changes to “Ready for Switching On”.
• Control word 1 bit 1 = 0 (OFF2): Coast down

The drive immediately goes to pulse suppression and the status changes to
“Switching On Inhibited”.
• Control word 1 bit 2 = 0 (OFF3): Quick Stop.

The drive travels to zero speed at the torque limit. The stopping process
cannot be interrupted. After stopping, a pulse suppression is carried out and
the status changes to “Switching On Inhibited”.

Pulse enable Select the parameter that controls the pulse enable function here.
OFF 1 (Priority 3) Select the parameter that controls the OFF 1 function here.
OFF 2 (Priority 1) Select the parameters that control the OFF 2 function here.
OFF 3 (Priority 2) Select the parameters that control the OFF 3 function here.
Ramp-down time
OFF 3 For the command OFF 3, specify here the time required for the motor to
decelerate from maximum speed to standstill.

Control word 2 The control word 2 is a group of a further 16 internal binary signals.
Drive data set (DDS) Using the drive data sets (DDS) you can parameterize several inverter functions
differently and then switch over between the different settings.
The associated parameters are indexed (index 0, 1, 2 or 3). Using control
commands select one of the four indices and therefore one of the four saved
settings.
The settings in the inverter with the same index are known as drive data set.
Depending on the CU there are either one or several drive data sets.
Application example:
You connect different motors to one inverter. Depending on the particular motor,
the inverter must operate with the associated motor data and the appropriate
ramp-function generator.

Status word 1 The status word 1 accesses the most important signals as a 16-bit data word
via the current state of the inverter.

Status word 2 The status word 2 displays further signals regarding the current state of the
inverter as a 16-bit data word.

Display The states of the control and status words are stored in parameters and can be
displayed graphically:
>> Online & diagnostics > Control / Status word
Parameters The control and status words can be found in the following parameters:
• Control word 1: r54
• Control word 2: r55
• Status word 1: r52
• Status word 2: r53
• Status word closed loop control: r56

Training Document 6 - 10 Control signals and Signal interconnections
BICO technology Using the BICO technology (Binector Connector Technology) it is possible to
freely interconnect process data via the "normal" drive parameters. Here, all
freely interconnectable values (e.g. frequency setpoint, frequency actual value,
current actual value, etc.) are defined as "connectors", and all freely
interconnectable digital signals (e.g. digital input status, ON/OFF, signaling
functions when exceeding / falling below a limit, etc.) are defined as "binectors".
In a drive unit, there are a large number of interconnectable input and output
variables as well as internal control variables. BICO technology allows you to
adapt the drive unit in line with different requirements.
Binectors A binector is a digital (binary) signal without a unit which can assume the value
0 or 1. Binectors are always related to functions, whereby they are subdivided
into binector inputs and binector outputs.
Here the binector input is always denoted by a "P" parameter plus "BI" attribute
(e.g.: P0731 BI: Function digital output 1), whereas the binector output is always
represented by an "r" parameter plus "BO" attribute (e.g.: r0751 BO: ADC status
word).

Connector A connector is a value (16 or 32 bit), which can contain not only a normalized
variable (dimensionless) but also a variable with a dimension.
BI Binector input, signal sink ("P" parameter)
BO Binector output, signal source ("r" parameter)
CI Connector input, signal sink ("P" parameter)
CO Connector output, signal source ("r" parameter)
Interconnection When interconnecting, the signal source (BO/CO) is entered at the signal sink
(BI/CI).
Example P0840 = P751.0

The parameter P0840 is a binector input and has the function "On/Off1".
The binector output P0751.0 is assigned to this parameter. This BO is set if the
analog input does not deliver a signal.

Assignments Parameters can be used to select which signal is present at the analog output.
Factory setting: P0771 = r21 (output speed smoothed). The function numbers
correspond to the associated observation parameters.
This enables nearly all observation parameters to be entered in P0771.
The observation parameters which are possible are marked with CO in the
parameter list.

Startdrive software The Startdrive commissioning software provides screens that make the handling
of BICO technology much easier. This essentially means that knowledge of
BICO technology is no longer required. The signals that you can interconnect
are displayed in plain text.

Logic operations Logic operations, which link several states (e.g. access control, plant status) to
a control signal (e.g. ON command), are required for controlling the inverter in a
wide variety of applications.
Control Up until now this was realized with a PLC (programmable logic controller) or
relay technology, resulting in additional costs within the plant.
Function blocks Alongside logical links, increasingly required in inverters are arithmetic
operations or stored elements, which form a new unit out of several physical
variables.
This simplified PLC functionality is available within G120 via the freely
programmable function blocks (FFB).

Logic These blocks can be used to define logic operations for signals. Examples:
• AND block: Two conditions must be fulfilled for the drive to start.
• OR block: There are 3 different sensors that supply a signal to start the
drive.
Calculating These blocks can be used to process the signals mathematically. Examples:
• Subtracter: The difference between two measured values at the analog
inputs can be determined.
• Comparator: Two measured values can be compared and the result
processed further in the form of a binary signal.
• Frequency polygon: Can be used to enter characteristic curves.

Pulse generator A pulse of selectable length can be generated from an increasing or falling
edge.
Timer The time-function blocks described above are referred to in other documents as
Timers
RS flip-flop A flip-flop is a bistable toggle switch. It has two stable states.

The RS flip-flop can be switched alternately via the set and reset input. If both
inputs are 0, nothing changes; if both inputs are 1, the reset input dominates.
Abbreviation: RSR = Reset-Set-Register
D flip-flop The output of a D flip-flop only changes if an increasing edge occurs at the clock
input C (Clock). Then the level of the signal input D (Data) is transferred to the
output.
However, this is dependent on the set and reset input. If the set and reset input
= 0, the signal will be accepted. Otherwise the reset input dominates.

Switches These blocks can be used to switchover between two signal sources. Example:
• Analog signal selector switch: It is possible to switch between two signal
sources
Limit monitor This block can be used to monitor the fill level, for example. This is independent
of the integrated PID controller.
Closed-loop control This can be used to implement simple control structures. Examples:
• PT1 smoothing element: A non-smooth signal transferred via the fieldbus
can be smoothed prior to further processing.
• Integrator: If the speed is integrated, the result for traversing mode is the
distance traveled.

Processing All free function blocks are called up within time slices (cycle time).
• The simple blocks can be calculated in the 8 ms cycle.
• The complex blocks are calculated in the 128 ms cycle at a maximum.
Slower processing The free blocks place an additional load on the CPU. If many blocks are
activated, the CPU may become overloaded. Then, blocks that are not time-
critical can be shifted to slower time slots.

Function block
diagrams The parameter list is sufficient for simple interconnections. For more complex
interconnections, you should refer to the function block diagrams.
Complexity BICO technology is a very powerful tool. Don't let the numerous options confuse
you! In most cases only one or two signals need to be changed.
Handling Always take care when establishing internal interconnections. Make a note of
which changes you perform.
Subsequent analysis is only possible with a certain amount of effort: by reading
out the changed parameters with Startdrive and checking all BI and CI
parameters. BICO parameters are color-coded and can be accessed via
separate menu commands. In addition, Startdrive offers a filter function.

Requirement You have completed exercise 5, chapter 3 (basic commissioning)
Task Clarify how the control signals work and are interconnected for operation via a
terminal strip!
1. Allow the drive to rotate. Switch the power supply off and on again.
Does the drive restart? ........................................................................
How does ON/OFF1 work: Level or edge? ..KKKKKKKKKKK
2. Determine control word 1:
>> G120_ > Online & diagnostics > Control/status words
Select the parameters of the control word:
>> G120_ > Parameter > Drive Functions > Shutdown functions
or
>> G120_ > Parameter > Parameter View p840 etc. and p1140, p1141
3. Which signals are present? How are bits 0 to 5 assigned?
• Bit 0 = 0 ON/OFF1 p840 = r722.0 means DIN0
• Bit 1 = ... ...KKKK......... p...KK = ...KKK means KK

Task Test the function of the signals responsible for switching the drive on and off!
1. Assign bits 0 to 5 of the control word with the digital inputs DI 0 to 5.

>> G120_ > Parameter > Inputs/outputs > Digital inputs
(signal sources)
or
>> G120_ > Parameter > Drive functions > Shutdown functions
>> G120_ > Parameter > Setpoint channel > Ramp-function generator
(signal target)
2. Allow the drive to rotate by switching on all the switches.
3. Test the effect when switching off the signals:
• DIN 0 = ON/OFF1 0 =KKKKKKKK 1=KKKKKKKK
• DIN 1 = KKKKK 0 =KKKKKKKK 1=KKKKKKKK

4. What is the relation between the three OFF signals?
Which signal needs to be switched on last?
KKKKKKKKKKKKKKKKKKKKKKKKKKKKKK

Task Determine which signals are output to the digital outputs DO 0 to 2 when
operating via terminal strip and determine other useful signals!
1. Clarify the assignment of the digital outputs:

>> G120_ > Parameter > Inputs/Outputs > Relay outputs
see also:
>> >> G120_ > Online & diagnostics > Control/status words
• DO 0:
p730 = KKKKK means: 0 = ...KKKKKK 1 = KKKKK...K
• DO 1:
• DO 2:
2. Select the parameters of the status word:

3. Name some signals which appear to be useful:
rKKKKK meaning: 0 = ...KKKKKK 1 = KKKKK...K

Task The following messages are to be output at the terminals:
• DO 0 Switching On Inhibited
• DO 1 Current Torque Limiting Active
• DO 2 Alarm Motor Over temperature
1. Assign:
• DO 0: Switching On Inhibited
> Status word 1
p730 = KKKKK Meaning: 0 = ...KKKKKK 1 = KKKKK...K
• DO 1: Current Torque Limiting Active
>> G120_ > Parameter > Operation mode > Torque limitation

• DO 2: Alarm Motor Overtemperature
>> G120_ > Parameter > Drive functions
> Messages and monitoring functions > Motor temperature
2. Allow the drive to rotate and monitor the LEDs on the training device.
• Switching On Inhibited:
TIP: Operate ON/OFF1, OFF2 and OFF3.
• Current Torque Limiting Active:
TIP: Run at 100 rpm and operate the brake.
• Alarm Motor Overtemperature:
TIP: Set the parameter for the motor temperature alarm threshold
to 30 or 40 ºC.

Task Use the user-friendly display in Startdrive to observe the signals from the
"Alarms“ and “Diagnostics overview”!
1. Allow the drive to rotate.

Switch the supply voltage off very briefly and back on again.
Which operating state appears on the unit?
..........................................................................
What information is shown in Startdrive?
>> G120_ > WINDOW detail view > Alarm display
KKKKKKKKKKKKKKKKKKK..........
>> G120_ > Online & diagnostics> > Drive enable signals
KKKKKKKKKKKKKKKKKKK..........
2. Acknowledge this state in Startdrive and switch on again according to the
specifications in the Diagnostic overview window
3. Switch off via OFF2 (DIN1) and OFF3 (DIN2).
4. Determine the data in the Diagnostics overview window:
>> G120_ > WINDOW detail view > Diagnostics overview
What order must now be taken for switching on?
Signal Operation
1. ................ .................
2. ................ .................
3. ................ .................
4. ................ .................

Task Create different error messages one after the other for evaluation later on!
1. Allow the drive to rotate.

Switch the supply voltage off very briefly and back on again. F30003
Acknowledge this fault.
2. Set the parameter for the motor temperature fault threshold to e.g. 40 ºC.
>> G120_ > Drive functions > Messages /monitoring > Motor temperature
Allow the drive to rotate until the threshold is reached. F7011
3. Parameterize an External Fault 1 to DI 5
>> G120_ > Parameters > Parameter view > p2106
and switch DI 5 = 0 F7860
Deactivate External Fault 1 again: DI 5 = 1
4. Run at maximum speed. Operate and release the brake. F7901
Task Determine the entries in the error memory!
1. Select the following window:

>> G120_ > Online & diagnostics >> Diagnostics > Alarm history
• How many faults have been stored? ...............
• What is the maximum number of faults that can be stored? ...............
• Is this alarm history saved against power failure? ...............

Task Find out more information about the error messages by reading out the
assigned fault values!
1. Double klick on the “Fault code” to open the information system on this error.
2. What reactions do the errors produce?
Fault code Reaction?
• F30003 ..................
• F7011 ..................
• F7860 ..................
• F7901 ..................
3. Can all errors be acknowledged immediately after they occur?

If not, why not?
Fault code Immediate acknowledgement possible?
• F30003 ..................
• F7011 ..................
• F7860 ..................
• F7901 ..................

Task The drive should only start when two external signals are present at the same
time. This can be an ON signal, for example, and a closed door contact in
addition.
Solve the requirement by using a free block!
1. Select the AND block "AND 0“:

>> G120_ > Parameter > Application functions > Free blocks
or
"SINAMICS G120 Control Units K, List Manual“,
Chapter 3.17 "Free function blocks“, from function block diagram 7210 and
>> G120_ > Parameter > Parameter View
2. Enter “AND 0“ as search term in the "Parameter text" area.
3. Connect DI 0 and DI 1 to the inputs of the AND block.
Make sure that the signals are not double-wired,
e.g. in the AND block and to "Reverse".
4. Set the further inputs of the AND block to "1“ to ensure that the function
works.
5. Connect the output of the AND block with the ON/OFF1 signal in the
shutdown functions
AND block AND 0 = r...............
>> G120_ > Parameter > Drive functions > Shutdown functions
6. Assign the block to a runtime group with sampling time 128 ms.
"SINAMICS G120 Control Units K, List Manual“,
Chapter 3.17 "Free function blocks“, from function block diagram 7200
7. Test the function.

Task The drive may only start after a certain delay. This can, for example, be
necessary due to the buildup of an oil pressure or the opening of an external
interlock.
Extend your interconnection with a further free block!
1. Select a delay block.

>> G120_ > Parameter > Application functions > Free blocks
or
"SINAMICS G120 Control Units K, List Manual“, Chapter 3.17
"Free function blocks“, from function block diagram 7232
>> G120_ > Parameter > Parameter View
Enter “PDE 0“ as search term in the "Parameter text" area
2. Connect the input from the delay block to the output of the AND block
3. Connect the output of the delay block with the signal ON/OFF1 in the control
word
• Output delay block PDE 0 = r...............
>> G120_ > > Drive functions > Shutdown functions
4. Enter a delay time of 5 sec.
• p........................ = ........................
5. Assign the block to a runtime group with sampling time 128 ms
"SINAMICS G120 Control Units K, List Manual“, Chapter 3.17
"Free function blocks“, from function block diagram 7200
6. Check the execution sequence
• AND block AND 0 run sequence position KKKK
• Delay block PDE 0 run sequence position KKKK
7. Test the function.
8. Take back the parameterization of ON/OFF1 to DIN 0 and OFF2 to DIN1.

Task To display signals dependent on time the tool trace can be used. The trace can
be used to detect faults, do optimize the drive or to document the drive status.
In this exercise the trace is used to display how the drive accelerates.
A trigger is defined to start the trace and the measurements is loaded to the PG.
1. Add a new trace:
>> G120_ > Traces > Add new trace
and set the parameters as follows:
2. Signals:
• r62: Speed setpoint after the filter
• r63[0]: Speed actual value, unsmoothed
• r78: Current actual value, torque generating
3. Trace:
• Duration: 4000 ms, adapt “Cycle“
4. Trigger:
• Type: Trigger on tag – rising signal
• Tag: r62: Speed setpoint after the filter
• Threshold: 0.1 rpm
• Pretrigger: 100 ms
5. Store the project and “Transfer trace configuration to device"
6. Start the trace

Task After loading the trace is started automatically and is in the state “Waiting for
trigger”.
1. Start the drive with the digital input DI0. The trace starts and after finishing
the measurement the data are transferred to the PG.
2. To display the signals in a way to analyze them you can use the scaling and
the coloring.
3. To compare the signals the scaling must be set to the same values for all the
signals.


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

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Command data set

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• Control word 1 bit 1 = 0 (OFF2): Coast down

• Control word 1 bit 2 = 0 (OFF3): Quick Stop.

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Example P0840 = P751.0

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RS flip-flop A flip-flop is a bistable toggle switch. It has two stable states.

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• Bit 1 = ... ...KKKK......... p...KK = ...KKK means KK

• Bit 2 = ... ...KKKK......... p...KK = ...KKK means KK

• Bit 3 = ... ...KKKK......... p...KK = ...KKK means KK

• Bit 4 = ... ...KKKK......... p...KK = ...KKK means KK

• Bit 5 = ... ...KKKK......... p...KK = ...KKK means KK

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1. Assign bits 0 to 5 of the control word with the digital inputs DI 0 to 5.

• DIN 0 = ON/OFF1 0 =KKKKKKKK 1=KKKKKKKK

• DIN 1 = KKKKK 0 =KKKKKKKK 1=KKKKKKKK

• DIN 2 = KKKKK 0 =KKKKKKKK 1=KKKKKKKK

• DIN 3 = KKKKK 0 =KKKKKKKK 1=KKKKKKKK

• DIN 4 = KKKKK 0 =KKKKKKKK 1=KKKKKKKK

• DIN 5 = KKKKK 0 =KKKKKKKK 1=KKKKKKKK

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1. Clarify the assignment of the digital outputs:

2. Select the parameters of the status word:

3. Name some signals which appear to be useful:

rKKKKK meaning: 0 = ...KKKKKK 1 = KKKKK...K

rKKKKK meaning: 0 = ...KKKKKK 1 = KKKKK...K

rKKKKK meaning: 0 = ...KKKKKK 1 = KKKKK...K

rKKKKK meaning: 0 = ...KKKKKK 1 = KKKKK...K

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p731 = KKKKK Meaning: 0 = ...KKKKKK 1 = KKKKK...K

p732 = KKKKK Meaning: 0 = ...KKKKKK 1 = KKKKK...K

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1. Allow the drive to rotate.

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1. Allow the drive to rotate.

Task Determine the entries in the error memory!

1. Select the following window:

• How many faults have been stored? ...............

• What is the maximum number of faults that can be stored? ...............