Changeover, CU240S to CU240E-2

(Firmware V4.4)
SINAMICS G120

FAQ July 2012

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Question
What do I have to observe if I wish to replace a member of the CU240S family
(CU240S, CU240S DP, CU240S DP-F, CU240S PN or CU240S PN-F) of
SINAMICS G120 by a CU240E-2 (Firmware V4.4)?

Answer
To respond to this question with the appropriate amount of detail, follow the
instructions and notes listed in this document.

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 Table of contents

Table of contents
1 Presentation of SINAMICS G120 CU240E-2...................................................5
1.1 Restrictions between CU240S and CU240E-2 ...................................6
1.2 Adaptations that must be made when making the changeover ...........7
2 Hardware.........................................................................................................9
2.1 Dimensions .......................................................................................9
3 IO interface ...................................................................................................10
3.1 Terminal assignment ....................................................................... 10
3.2 Digital inputs....................................................................................11
3.2.1 Changes to the number of digital inputs ........................................... 11
3.2.2 Changes to the fail-safe inputs (F-DI)............................................... 11
3.2.3 Transferring the status of the F-DI via PROFIsafe ............................ 11
3.2.4 Changing the reference potential and PNP / NPN logic .................... 11
3.2.5 Changed BICO interconnection of the digital inputs..........................12
3.2.6 Simulating the digital inputs ............................................................. 12
3.2.7 Monitoring the load/speed via a digital input..................................... 12
3.3 Digital outputs..................................................................................13
3.3.1 Modified parameter numbers ........................................................... 13
3.3.2 Hardware change DO1 .................................................................... 13
3.4 Analog inputs...................................................................................13
3.4.1 Modified factory setting.................................................................... 13
3.4.2 Changed ADU dead zone (p761) ..................................................... 13
3.4.3 Simulation of the analog inputs ........................................................ 14
4 Communication ............................................................................................15
4.1 GSD files.........................................................................................15
4.2 Routing through a CPU.................................................................... 15
4.3 Teleservice......................................................................................16
4.3.1 Teleservice via a CPU ..................................................................... 16
4.3.2 Teleservice directly to the fieldbus ................................................... 17
4.4 Slave-to-slave traffic ........................................................................ 18
4.5 Direct HMI connection ..................................................................... 18
5 Local operator control via BOP-2 or IOP..................................................... 19
5.1 Manual operation with BOP-2 / IOP ................................................. 19
5.2 Status signals of the BOP-2 / IOP operator control panels................ 19
6 Parameterization ..........................................................................................20
6.1 Elimination of closed-control modes................................................. 20
6.2 Changed reference quantities .......................................................... 20
6.3 Fixed setpoints that can be freely used ............................................ 20
6.4 Parameterizing the command and setpoint sources ......................... 20
6.5 Expanding the command/drive data sets.......................................... 20
6.6 Change for the second ramp function via JOG ramp-function
generator.........................................................................................21
6.7 U/f points along a characteristic (U/f with programmable
characteristic) ..................................................................................21
6.8 Speed-dependent controller adaptation............................................ 21
6.9 Operating hours counter .................................................................. 21
6.10 Changes to the braking chopper ...................................................... 21
6.11 Expansion of the motor holding brake function ................................. 21
6.12 Changes to the free function blocks (FFBs)...................................... 22
6.13 Changes to the phase failure monitoring .......................................... 22

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 Table of contents

6.14 Change, operator panel LED can be deactivated ............................. 22

6.15 Wobbulation generator has been eliminated .................................... 22
6.16 Positioning down ramp has been eliminated .................................... 22
6.17 Memory card ...................................................................................22
6.17.1 Transferring a project from CU240S into the CU240E-2 ................... 22
6.17.2 Handling memory cards................................................................... 22
7 Safety functions ...........................................................................................23
7.1 New / extended safety functions ...................................................... 24
7.1.1 Extension SS1.................................................................................24
7.1.2 Extension to SLS.............................................................................25
7.1.3 New safety function SDI (Safe Direction) ......................................... 25
7.1.4 New safety function SSM (Safe Speed Monitor)............................... 26
7.2 Standard STARTER parameterizing screen forms ........................... 26
7.3 Simplified parameterization.............................................................. 26
7.4 Offline safety parameterization......................................................... 26
7.5 Acceptance report ...........................................................................27
7.6 Changing the reference quantity ...................................................... 27
7.7 Changes to the fail-safe inputs (F-DI)............................................... 27
7.8 SBC is no longer supported ............................................................. 27
7.9 Group drives....................................................................................27
7.10 Changes in the PROFIsafe telegram................................................ 28
7.10.1 Previous CU240S PROFIsafe telegram 30....................................... 28
7.10.2 New CU240E-2 PROFIsafe telegram 30 .......................................... 28
7.10.3 New CU240E-2 PROFIsafe telegram 900 ........................................ 29
7.11 Transferring the status of the F-DI via PROFIsafe ............................ 29
8 Drive fault messages....................................................................................30

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 1 Presentation of SINAMICS G120 CU240E-2

1 Presentation of SINAMICS G120 CU240E-2

SINAMICS G120 CU240E-2 (Firmware V4.4) has, as successor to the CU240S
(CU240S, CU240S DP and CU240S DP-F), the following new and additional
properties:

Communication (see Chapter 3 for details)

- Slave-to-slave communication for direct data exchange between converters.

Safety functions (for details, refer to Chapter 7)

- The STO (Safe Torque Off) safety function is integrated in all versions as
standard.
- The –F versions of the CU240E-2 (CU240E-2 –F, CU240E-2 DP-F and
CU240E-2 PN-F) have the following safety functions: STO (Safe Torque Off),
SS1 (Safe Stop 1), SLS (Safely Limited Speed) with up to 4 parameterizable
limit values, SSM (Safe Speed Monitoring) and SDI (Safe Direction). Just as
before, speed feedback using an encoder is not required for these safety
functions.
- Direct control of the safety functions via onboard F-DIs or via PROFIsafe
(Profibus and Profinet) from a fail-safe control system.
- Fail-safe transfer of the F-DI status via PROFIsafe for the CU240E-2 DP-F and
CU240E-2 PN-F. As a consequence, the F-DI of the converter can be used as
distributed I/O of an F control system.
- Maximum value of the SS1 down ramp has been increased (CU240S: max.
99s referred to 200Hz CU240E-2: max. 1000s referred to the reference
speed (e.g. 1500 rpm)).

Commissioning and optimization

- Increased degree of operator friendliness using the BOP-2 operator panel.
- By using the IOP, faster local commissioning using the commissioning wizard,
simpler optimization of the parameterization and fault diagnostics using plain
text display.
- User-friendly, graphic commissioning using the STARTER parameterizing
software, which is free-of-charge. Optimization of the parameterization using
the trace function. Connections established via the USB port or via fieldbus
(Profibus and Profinet).
- Optimized optional storage of the parameter assignments in an MMC / SD card
so that the devices can be quickly replaced when service is required.

Same standard parameter structure as for SINAMICS S110 and S120

- One common firmware basis and standard parameterizing screen forms for all
SINAMICS converters. Therefore, it is simpler to get to know a member of the
SINAMICS family that has not been used up until now.

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 1 Presentation of SINAMICS G120 CU240E-2

1.1 Restrictions between CU240S and CU240E-2

Unfortunately, it is still not possible to completely replace the CU240S family by the
CU240E-2 family. The following overview will provide you with a first selection help
as to which CU240S can be replaced with which CU240E-2 version.

Previous concept New concept with the CU240E-2 family

Is integrated Closed-loop
Communication Implemented with safety technology control mode Replaced by Safety technology Comments
used? with encoder ?
By using STO, external
safety relays and contactors
No or realized No CU240E-2 STO
may be able to be
CU240S using external
eliminated
components
Presently, no direct replacement possible -> Alternative, CU305
Yes
CU305 DP STO / SS1 / SBC
No
CU240E-2 STO
communication SBC is not supported by the
No STO / SS1 / SLS /
or RS485 / USS CU240E-2 -F CU240E-2 family
SDI / SSM
CU240S DP-F
Presently, no direct replacement possible -> Alternative CU305
or Yes
CU240S PN-F With Extended
Yes Safety license
CU305 DP
STO / SS1 / SLS /
SDI / SSM / SBC
By using STO, external
safety relays and contactors
No or realized No CU240E-2 DP STO
may be able to be
CU240S DP using external
eliminated
components
Presently, no direct replacement possible -> Alternative, CU305
Yes
CU305 DP STO / SS1 / SBC
CU240E-2 DP STO
Profibus SBC is not supported by the
No STO / SS1 / SLS /
CU240E-2 DP-F CU240E-2 family
SDI / SSM
Presently, no direct replacement possible -> Alternativ,e CU305
CU240S DP-F Yes
With Extended
Yes Safety license:
CU305 DP
STO / SS1 / SLS /
SDI / SSM / SBC
By using STO, external
safety relays and contactors
No or realized No CU240E-2 PN STO
may be able to be
CU240S PN using external
eliminated
components
Presently, no direct replacement possible -> Alternative, CU305
Yes
CU305 PN STO / SS1 / SBC
CU240E-2 PN STO
Profinet SBC is not supported by the
No STO / SS1 / SLS /
CU240E-2 PN-F CU240E-2 family
SDI / SSM
Presently, no direct replacement possible -> Alternative, CU305
CU240S PN-F Yes
With Extended
Yes Safety license
CU305 PN
STO / SS1 / SLS /
SDI / SSM / SBC

With the changeover from CU240S to CU240E-2, you must observe the following
restrictions:
- Digital inputs:
o The CU240E-2 family has only 6 digital inputs, contrary to the CU240S
family
- Fail-safe inputs:
o The CU240E-2 family has no separate F-DIs, contrary to the CU240S
family. The F-DIs of the CU240E-2 are formed from two standard
digital inputs
- Encoder interface:
o The CU240E-2 family has no interface for a speed controller, and as a
consequence, only supports encoderless (sensorless) closed-loop

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 1 Presentation of SINAMICS G120 CU240E-2

control modes (U/f, sensorless vector control (SLVC) and sensorless

torque control). As an alternative, SINAMICS S110 can be used with
CU305

1.2 Adaptations that must be made when making the

changeover
As a result of the partially restricted functional scope, but also as a result of the
expanded functionality of the CU240E-2 family with respect to the CU240S family,
changes to the CU240S configuration are required. These will now be
subsequently listed and explained in detail in the following chapters.
In addition, new functions will be listed in the individual chapters.

Hardware design (see Chapter 2)

- Changes to the height and depth of the CU.

IO interface (see Chapter 3)

- Fewer DIs (CU240S: 9 DIs / CU240S DP-F and CU240S PN-F: 6 DIs to 6 DIs
for the CU240E-2 family).
- No separate F-DIs, for the CU240E-2 family, these are formed from two
standard DIs.
- No speed encoder interface.
- Changes to the terminal assignment regarding NPN/PNP logic and reference
potential of the digital inputs.
- Changeover, DO1 to the transistor output.
- Analog inputs; dead zone function has been modified.

Communication (refer to Chapter 4)

- Existing programs to control a SINAMICS G120 with CU240S via a fieldbus
from a PLC, in most cases can still be used for the CU240E-2. For example, if
parameters are accessed via cyclic or non-cyclic communication, then the only
change that is required is as a result of the modified parameter numbers.
- There are some restrictions regarding routing and teleservice functions.

Local operator control via BOP-2 or IOP (see Chapter 5)

- Changes to the manual/automatic changeover.
- The BOP / IOP operator control elements can no longer be used as BICO
source.

Parameterization (refer to Chapter 6)

- It is not possible to directly migrate from CU240S projects to CU240E-2. The
drive must be re-commissioned.

Safety functions (refer to Chapter 7)

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 1 Presentation of SINAMICS G120 CU240E-2

- As a result of the more extensive safety functions of the CU240E-2, a direct

parameter migration is not possible. The safety functions must be re-
commissioned.
- It is necessary to adapt the safety program in the F-CPU, in order to use the
new safety functions (4 SLS limit values, SDI and SSM).
- The CU240E-2 family does not support the SBC (Safe Brake Control) safety
function.

Drive fault messages/signals (refer to Chapter 8)

- The drive fault messages/signals of the CU240E-2 have changed when
compared to the CU240S. If these are to be displayed on an HMI for diagnostic
purposes, then the new fault messages must be integrated into the HMI.

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 2 Hardware

2 Hardware
2.1 Dimensions
Changed dimensions between the CU240S and CU240E-2
Width:
No change
Height without fieldbus connector (177 mm for CU240S, with shield connection
plate, 220mm):
199mm
with shield connection plate, 255mm
Depth (63mm for the CU240S with/without BOP):
39mm without BOP-2 / IOP
50mm with BOP-2
60mm with IOP

CU240S CU240E-2

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 3 IO interface

3 IO interface
3.1 Terminal assignment
The terminals of the CU240S will be compared with those of the CU240E-2 family.
Changes between the CU240S and CU240E-2 have been color coded.
CU240S CU240E-2
Function Terminal Name Terminal Name Note
1 +10V OUT 1 +10V Out
Power supply AI
2 0V OUT 2 GND OUT
3 AI0+ 3 AI0+
Analog input AI0 Can also be used as additional digital input (DI11)
4 AI0- 4 AI0-
Digital input 0 5 DI0 5 DI0 For the CU240E-2 F and E-2 DP F, the two DIs can be re-parameterized
Digital input 1 6 DI1 6 DI1 to form F-DI0

Digital input 2 7 DI2 7 DI2 For the CU240E-2 F and E-2 DP F, the two DIs can be re-parameterized
Digital input 3 8 DI3 8 DI3 to form F-DI1

Power supply DIs 9 U24V 9 +24V Out

10 AI1+ 10 AI1+
Analog input AI1 Can also be used as additional digital input (DI12)
11 AI1- 11 AI1-
12 AO0+ 12 AO0+
Analog output AO0
13 AO0- 13 GND
14 PTC+ 14 T1 Motor Possibility of connecting PTC, KTY 84 and Thermoclick (bimetallic)
Thermo sensor
15 PTC- 15 T2 Motor sensors

For the CU240E-2 and E-2 D the two DIs can be re-parameterized to form
Digital input 4 16 DI4 16 DI4
F-DI0
For the CU240E-2 F and E-2 DP F the two DIs can be reparameterized to
Digital input 5 17 DI5 17 DI5 form F-DI2
18 DO0 NC 18 DO0 NC
Relay output DO0 19 DO0 NO 19 DO0 NO
20 DO0 COM 20 DO0 COM
21 DO1 NO 21 DO1+
Relay/digital output DO1 Changeover from relay to transistor output
22 DO1 COM 22 DO1-
23 DO2 NC 23 DO2 NC
Relay output DO2 24 DO2 NO 24 DO2 NO
25 DO2 COM 25 DO2 COM
26 AO1+ 26 AO1+
Analog output AO1
27 AO1- 27 GND
Reference potential for +24V 28 U0V 28 GND
Pin 1 0V
29 RS485 -A Pin 2 RS485P
RS485 interface RS485 interface for CU240E-2 and CU240E-2 F via separate connector
30 RS485 -B Pin 3 RS485N
Pin 4 Shield

External 24Vpower supply of the CU, 31 +V24 IN 31 +24V IN

instead of supply via the PM
32 0V IN 32 GND IN
Power supply, speed encoder 33 ENC+ Supply The CU240E-2 family has no speed encoder interface
Reference potential for DI1, 3 and 5 34 DI COM2 For NPN logic, connect both terminals with terminal 28
Reference potential for DI0, 2 and 6 69 DI COM1 For PNPlogic, connect both terminals with 9

Digital input 6 40 DI6

Digital input 7 41 DI7 Digital inputs DI6 … DI8 are not available for the CU240E-2 family
Digital input 8 42 DI8
60 FDI0A
Fail-safe digital input 0
61 FDI0B The CU240E-2 family does not have any separate F-DIs, these are formed
62 FDI1A from standard DIs (see, for example terminals 16 and 17)
Fail-safe digital input 1
63 FDI1B
70 ENC AP
71 ENC AN
72 ENC BP
Speed encoder interface The CU240E-2 family has no speed encoder interface
73 ENC BN
74 ENC ZP
75 ENC ZN

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 3 IO interface

3.2 Digital inputs

3.2.1 Changes to the number of digital inputs

Contrary to the CU240S (up to 9 DIs), the CU240E-2 family only has 6 digital
inputs. However, the two analog inputs, if these are not required, can be used as
two digital inputs.

3.2.2 Changes to the fail-safe inputs (F-DI)

The CU240E-2 family has, contrary to the CU240S family, no separate fail-safe
digital inputs. For the CU240E-2, the F-DIs are formed from two standard DIs (see
Chapter 3.1)
- CU240E-2, CU240E-2 DP and CU240E-2 PN up to 1 F-DI
- CU240E-2 –F, CU240E-2 DP-F and CU240E-2 PN-F up to 3 F-DIs

3.2.3 Transferring the status of the F-DI via PROFIsafe

New function
Using PROFIsafe, for the CU240E-2 DP-F, the status of the F-DIs can be
transferred to the F-CPU in a safety-relevant fashion so that these are available as
distributed F I/O. For details, refer to Chapter 7

3.2.4 Changing the reference potential and PNP / NPN logic

The reference potential terminal 69 on the CU240S was, for the CU240E-2,
distributed over two terminals (terminals 69 and 34). Also refer to Chapter 3.1.
Terminal 69: Reference potential for DI0, DI2 and DI4
Terminal 34: Reference potential for DI1, DI3 and DI5

The PNP / NPN logic changeover of the digital inputs is, for the CU240E-2, no
longer realized by parameterization (CU240S: p725) and the wiring; it is only
defined using the input wiring.
For an internal power supply
- For PNP logic: Connect terminals 34 and 69 with terminal 28.
- For NPN logic: Connect terminals 34 and 69 with terminal 9.
For an external power supply
- For PNP logic: Connect terminals 34 and 69 with the system ground.
- For NPN logic: Connect terminals 34 and 69 with the system 24 V.
For more information refer to the List Manual Link (Chapter 2, function diagram
2220).

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 3 IO interface

3.2.5 Changed BICO interconnection of the digital inputs

Previously, the digital inputs for BICO interconnection had to be enabled using the
value 99; this is now no longer required. The interconnection can now be made
directly without having to use p701…p706 or p701...p709 (no longer available in
CU240E-2). In addition, inverted signals of the digital inputs are available.

CU240S CU240E-2

3.2.6 Simulating the digital inputs

New function
The digital inputs can now be simulated for test purposes using the STARTER
parameterizing software.

3.2.7 Monitoring the load/speed via a digital input

New function
Using this function, load failure can be monitored as well as a speed deviation. For
details, refer to the operating instructions Link (Chapters 7.9.5 and 7.9.6).

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 3 IO interface

3.3 Digital outputs

3.3.1 Modified parameter numbers

The parameter numbers of the DOs are shifted in the expert list by one position (for
example DO0: CU240S = p731, CU240E-2 = p730).

3.3.2 Hardware change DO1

DO1 (terminal 21 / 22) was changed from being a relay output (CU240S) to a
transistor output (CU240E-2).

3.4 Analog inputs

3.4.1 Modified factory setting

The factory setting was changed from 0 – 10V (CU240S) to +/- 10V (CU240E-2).

3.4.2 Changed ADU dead zone (p761)

This parameter is no longer shown in the graphic display, but is still in the expert
list.

CU240S

The following setting should be made in order to implement a wire break

monitoring function as in the CU240S:
- AI0: p756[0] 1 (for 2-10V) or 3 (for 4-20mA) and p761[0] 0
- AI1: p756[1] 1 (for 2-10V) or 3 (for 4-20mA) and p761[1] 0

Using this function in the CU240S, if the analog values around 0 V are
suppressed, then this function can only be implemented by using FFBs (free
function blocks). We are presently working on an integrated solution.

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 3 IO interface

3.4.3 Simulation of the analog inputs

New function
Now, the analog inputs can be simulated for test purposes using the STARTER
parameterizing software.

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 4 Communication

4 Communication
Existing programs to control a SINAMICS G120 with CU240S via a fieldbus from a
PLC, in most cases can still be used for the CU240E-2. For example, if parameters
are accessed via cyclic or non-cyclic communication, then the only change that is
required is as a result of the modified parameter numbers.
In order to use the new or extended safety functions, the safety programs in an F-
CPU must be correspondingly adapted (refer to Chapter 7)

4.1 GSD files

The new GSD files are required for the CU240E-2 family. These can be
downloaded under the following link

4.2 Routing through a CPU

For routing beyond network limits (e.g. IE to Profibus DP), the CPU must support
the routing protocol data set. In addition, just as before, DriveES Basic is required.
The following CPUs support data set routing:
- ET200S
IM151-8 PN/DP CPU in conjunction with the DP master module
- SIMATIC S7-300
CPU313C-2 DP from version V3.3
CPU314C-2 DP from version V3.3
CPU314C-2 PN/DP from version V3.3
CPU315-2 DP from version V3.0
CPU315-2 PN/DP from version V3.1
CPU317-2 DP from version V3.3
CPU317-2 PN/DP from version V3.1
CPU319-3 PN/DP from version V2.7
- SIMATIC S7-400 CPUs from version V5.1
- WinAC RTX from version 2010, update 1 with CP5603,
CP5613 or CP5623

Presently, the following systems do not support data set routing:

- SIMATIC S7-1200
- WinAC MP
- SIMOTION

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 4 Communication

4.3 Teleservice
4.3.1 Teleservice via a CPU

A Teleservice Adapter II and a CPU, which is listed under Routing (Chapter 4.2) and which supports data set routing, are required.

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 4 Communication

4.3.2 Teleservice directly to the fieldbus

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 CU240E-2 PN, it is possible using the Teleservice Adapter IE Basic.

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 4 Communication

4.4 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 (more detailed information is provided in the
Operating Instructions (Chapter 6.1.4.4) Link

4.5 Direct HMI connection

A direct connection between an HMI and a CU240E-2 to read out and change drive
parameters without an intermediate CPU is not supported.
Read-parameters from the converter via the CPU and then transfer them to the
HMI.

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 5 Local operator control via BOP-2 or IOP

5 Local operator control via BOP-2 or IOP

For the CU240E-2, the BOP used by the CU240S, has been replaced by the BOP-
2 – its successor.

BOP BOP-2

The IOP is also available for user-friendly commissioning supported by wizards.

IOP

5.1 Manual operation with BOP-2 / IOP

For the CU240S, manual operation has been realized by changing over the
command data sets.
In the CU240E-2, the changeover to manual operation is realized using the manual
button of the BOP-2 / IOP. When activating manual operation, the control authority
is taken over by the BOP-2 / IOP. As a consequence, the parameterized/active
command and setpoint sources are decoupled.
Manual operation via the IOP/BOP-2 can be inhibited using parameter p806.
This inhibit can be permanent, but can also be selected using a digital input or a
fieldbus signal.
Manual operation via the BOP-2 / IOP permanently active: This function is not
possible. After power on, manual operation must be reactivated at the IOP / BOP-
2.

5.2 Status signals of the BOP-2 / IOP operator control

panels
The BOP-2 / IOP operator control panels can no longer be used as BICO sources
as for the CU240S (r19).

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 6 Parameterization

6 Parameterization
It is not possible to directly migrate from CU240S projects to CU240E-2 as a result
of the modified parameter structure.
The drive must be recommissioned using BOP-2, IOP or STARTER.

6.1 Elimination of closed-control modes

As the CU240E-2 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) Possibly use the
CU305 (SINAMICS S110)

6.2 Changed reference quantities

The reference quantities (p2000 … 2004) apply in the CU240E-2 as standard for all
data sets. In addition, the reference quantities have been expanded by the
reference temperature (p2006).
In the CU240E-2, the speed setpoint and actual value no longer refer to Hz but to
rpm; this means that it is no longer necessary to convert the required speed into a
frequency.

6.3 Fixed setpoints that can be freely used

New function
Fixed setpoints that can be freely used can be defined in p2900 / p2901 (+/-
100.00%) and p2930 (+/- 100000.00 Nm). In addition, fixed setpoints that are
already defined are available in r2902 [0 … 14].

6.4 Parameterizing the command and setpoint sources

New function
In the drive, the corresponding macros can be selected via p15 (e.g. during the
quick commissioning), via which the interfaces (command source, setpoint source,
I/O interconnection) can be adapted to the corresponding application far faster than
before. However, at the present time it is only possible to access p15 online (a
change is planned in STARTER V4.3).
Simplified parameterization. For details, refer to the operating instructions Link
(Chapters 3.4.5).

6.5 Expanding the command/drive data sets

There are now up to 4 command data sets (CDS) and up to 4 drive data sets
(DDS) available in the CU240E-2. Contrary to the CU240S, these must now first be
enabled using parameter p170 (CDS) or p180 (DDS).

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6.6 Change for the second ramp function via JOG ramp-
function generator
It is no longer possible to use the JOG ramp-function generator to implement a
second ramp function.
However, when using the data set changeover (DDS), up to 4 different
parameterizable ramp functions are now available. The data set changeover can
be implemented in operation via digital inputs or via the fieldbus. For details, refer
to the operating instructions Link (Chapter 7.11).

6.7 U/f points along a characteristic (U/f with

programmable characteristic)
Contrary to the CU240S (3 voltage points and 3 frequency points along a
characteristic), the CU240E-2 has 4 voltage/frequency points, which means that
the characteristic can be more finely parameterized.
If the additional points are not required, then set points 3 and 4 to the same
value.

6.8 Speed-dependent controller adaptation

New function
The Tn and Kp components of the controller can now be adapted as a function of
the speed in the CU240E-2 (refer to the list manual Link, function diagram 6050).

6.9 Operating hours counter

New function
The actual operating hours can be read out of p650 and a maintenance interval
can be activated in p651. Alarm A1590 is activated after the time in p651 has
expired.

6.10 Changes to the braking chopper

For the CU240E-2, the braking chopper is automatically activated when using a
PM240. The braking resistor must be externally protected against overload.
Connect the thermal sensor of the braking resistor to a DI of the converter and
interconnect this input with parameter p2106 "External fault 1". As a consequence,
for an overtemperature, fault F07860 "External fault 1" will be activated.
In addition, the VDCmax controller must be deactivated (for vector control:
p1240 0, for U/f: p1280 0).

6.11 Expansion of the motor holding brake function

The parameterization of the motor holding brake has been expanded. Various
modes are now available, where the brake, as before, can be opened or closed
from the process, but now also permanently or as a function of an external signal.
For details refer to the operating instructions Link or the STARTER screen
form.
The CU240E-2 does not support the SBC (Safe Brake Control) safety function.

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6.12 Changes to the free function blocks (FFBs)

The scope and functions of the free function blocks have been significantly
expanded over the CU240S. As a consequence, it was necessary to shift the
parameter numbers. Presently, the FFBs can only be interconnected via the expert
list.
For details refer to the list of manual Link (Chapter 2.12).

6.13 Changes to the phase failure monitoring

For the CU240E-2, the phase failure monitoring (CU240S, p291) is always active
and cannot be deactivated.

6.14 Change, operator panel LED can be deactivated

If a fieldbus is not used, then the OP-LED (operator panel LED) can be deactivated
using parameter p2030 0. For more detailed information refer to Link

6.15 Wobbulation generator has been eliminated

The wobbulation generator available in the CU240S is no longer available in the
CU240E-2.

6.16 Positioning down ramp has been eliminated

The positioning down ramp available in the CU240S (parameters p2480 … p2488)
is no longer available in the CU240E-2.
Implemented using a rapid traverse/crawl switchover based on FFBs or using a
SINAMICS S110 with EPOS (basic positioner).

6.17 Memory card

Contrary to the CU240S family (only MMC), for the CU240E-2 family, MMC and SD
cards can be used.

6.17.1 Transferring a project from CU240S into the CU240E-2

Projects of a CU240S on an MMC card cannot be transferred into a CU240E-2 as

a result of the changed parameter structure.
Clear the memory card and write the CU240E-2 project to it

6.17.2 Handling memory cards

Writing data to an MMC / SD card has been significantly simplified for the CU240E-
2. Parameter changes are automatically saved to the memory card.
For details, refer to the Operating Instructions in Chapter 4.6 Link and FAQ Link

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 7 Safety functions

7 Safety functions
The safety functions known from the CU240S have been expanded. The following
table provides an overview of the available safety functions and how they are
possibly controlled.

Device family G120

CU240E-2 DP CU240E-2 DP-F

Control Unit CU240E-2 CU240E-2 PN CU240E-2 F CU240E-2 PN-F
Firmware basis FW4.4
Standards:
EN 954-1 Cat. 3
IEC 61508 SIL 2
ISO 13849-1 Pld
Functions:
STO Yes Yes Yes Yes
SS1 No No Yes Yes
SSM No No No Yes
SDI No No Yes Yes
SLS No No Yes Yes
Number of SLS
0 0 1 4
limit values
SBC No No No No
Safety control:
F-DI Yes Yes Yes Yes
Number of F-DI up to 1 up to 1 up to 3 up to 3
PROFIsafe No Yes No Yes
F-DI and
Yes
PROFIsafe No Yes No
(only STO via F-DI)
together
F-DI status via
PROFIsafe No No No Yes
(telegram 900):

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
or that are continuously in the regenerating mode (also referred to the
function manual, Safety Integrated, Chapter 2.2 Link).
- The F-DIs are formed by combining 2 standard DIs through the appropriate
parameter assignment (also see Chapter 3.1).

More detailed information on the safety functions is provided in the Safety

Integrated Function Manual Link on the following Internet page Link

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 7 Safety functions

7.1 New / extended safety functions

7.1.1 Extension SS1

The SS1 safety function was extended as follows when compared to the CU240S
family.
- Braking the motor after activating SS1 can now be set using the following
parameter assignment:
Braking ramp monitoring:
After selecting SS1, SINAMICS G120 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, SINAMICS G120 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
CU240S (99s referred to 200Hz) in the CU240E-2 family to 1000s (referred
to the reference speed, e.g.1500 rpm).
Safely and reliably stopping high moments of inertia.
- For the CU240S family, 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 CU240E-2 family. The SS1
request remains active until STO is internally activated.

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 7 Safety functions

7.1.2 Extension to SLS

The SLS safety function was extended and revised as follows when compared to
the CU240S family.
- The various SLS modes of the CU240S family have been integrated in the
CU240E-2 family into one "mode". Simplify commissioning and the
possibility of implementing new safety concepts
- With the CU240E-2 DP F and CU240E-2 PN-F for control via PROFIsafe
there are now 4 SLS limit values available that can be parameterized.
New safety concepts can be implemented
- When activating SLS at standstill, current must flow through the motor
within 5 seconds. For the CU240S family, it is no longer necessary that a
minimum speed is reached during these 5 seconds. Simplifies the
control
- 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 active can be selected
to either be a STOP A (STO) or STOP B (SS1) (CU240S, only STO is
possible) In the case of a fault, the motor can now be safely braked and
no longer coasts down unbraked.

7.1.3 New safety function SDI (Safe Direction)

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

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7.1.4 New safety function SSM (Safe Speed Monitor)

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 the safety functions is provided in the Safety
Integrated Function Manual Link on the following Internet page Link

7.2 Standard STARTER parameterizing screen forms

New function
The STARTER parameterizing screen forms are now the same as the
parameterizing screen forms of the SINAMICS S110 and S120.
It is no longer necessary to get to know a new system when changing over to a
different SINAMICS converter

7.3 Simplified parameterization

New function
Just 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

7.4 Offline safety parameterization

New function
Just the same as for the SINAMICS S110 and S120, it is now also possible to
parameterize the safety functions offline.
Safety parameterization can already be prepared in an office environment.

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7.5 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

7.6 Changing the reference quantity

The speed-referred safety values no longer refer to Hz, but to rpm. Further, a gear
factor can now be parameterized
As a consequence, it is no longer necessary to convert between the
parameterization and the resulting motor speed.

7.7 Changes to the fail-safe inputs (F-DI)

The CU240E-2 family has, contrary to the CU240S family, no separate fail-safe
digital inputs. For the CU240E-2, the F-DIs are formed from two standard DIs (see
Chapter 3.1)
- CU240E-2, CU240E-2 DP and CU240E-2 PN up to 1 F-DI
- CU240E-2 –F, CU240E-2 DP-F and CU240E-2 PN-F up to 3 F-DIs

7.8 SBC is no longer supported

The CU240E-2 family does not support the SBC safety function. Use the CU305
(SINAMICS S110)

7.9 Group drives

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 still not been released for group
drives.

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 7 Safety functions

7.10 Changes in the PROFIsafe telegram

As a result of the more comprehensive safety functions of the CU240E-2 family,
the PROFIsafe telegram has been expanded.
In order to be able to use these functions, the safety program of the F-CPU must
be appropriately expanded.

7.10.1 Previous CU240S PROFIsafe telegram 30

* Selecting whether byte 0 / bit 4 or byte 1 / bit 0 should be used to control SLS is realized through the
appropriate parameter assignment

7.10.2 New CU240E-2 PROFIsafe telegram 30

* Extended Safety functions (CU240E-2 –F, CU240E-2 DP-F and CU240E-2 PN-F)

Changes to the CU240S PROFIsafe telegram (control word)

- Byte 0 / bit 4 SLS is controlled exclusively using this bit
- New: Byte 0 / bit 7 acknowledgment signal for safety fault messages
- New: Byte 1 / bit 1 and 2 select SLS limit value 1..4
- New: Byte 1 / bit 4 and 4 select the corresponding safe direction of
rotation

Changes to the CU240S PROFIsafe telegram (status word)

- Byte 0 / bit 4 speed under SLS limit value, exclusively using this bit
- New: Byte 0 / bit 7 fault, safety function
- New: Byte 1 / bit 1 and 2 feedback signal of active SLS limit value 1..4
- New: Byte 1 / bit 4 and 4 feedback signal of active safe direction of
rotation
- New: Byte 1 / bit 7 feedback signal, SSM status

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7.10.3 New CU240E-2 PROFIsafe telegram 900

* Extended Safety functions (CU240E-2 –F, CU240E-2 DP-F and CU240E-2 PN-F)

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 0…2)

7.11 Transferring the status of the F-DI via PROFIsafe

New function
Using PROFIsafe, for the CU240E-2 DP-F and CU240E-2 PN-F, the status of the
F-DIs can be transferred to the F-CPU in a safety-relevant fashion so that these
are available as distributed F I/O (see 7.9.3 telegram 900).

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 8 Drive fault messages

8 Drive fault messages

The drive fault messages/signals of the CU240E-2 have changed when compared
to the CU240S. If the fault texts are to be displayed on an HMI for diagnostic
purposes, then the corresponding fault texts can be downloaded under the
following Link

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