Drive System Application

Controlling the main contactor by using free function

blocks for MICROMASTER 4, SINAMICS G120 &
SINAMICS G120D

Application description
for MICROMASTER 4, SINAMICS G120 and SINAMICS G120D
 Warranty, liability and support

Controlling the main contactor by using free function blocks for ID-No: 22078212
MICROMASTER 4, SINAMICS G120 & SINAMICS G120D

Note The Application Examples are not binding and do not claim to be complete
regarding the circuits shown, equipping and any eventuality. The Application
Examples do not represent customer-specific solutions. They are only intended
to pro-vide support for typical applications. You are responsible in ensuring that
the de-scribed products are correctly used. These Application Examples do not
relieve you of the responsibility in safely and professionally using, installing,
operating and servicing equipment. When using these Application Examples, you
recognize that Siemens cannot be made liable for any damage/claims beyond
the liability clause described. We reserve the right to make changes to these
Application Examples at any time without prior notice. If there are any deviations
between the recommendations provided in these Application Examples and
other Siemens publications - e.g. Catalogs - then the contents of the other
documents have priority.
Copyright © Siemens AG 2008 All rights reserved
MainContactorControl_en_V1_4.doc

Version 1.4 Issue December 2010 2/28

 Warranty, liability and support

Controlling the main contactor by using free function blocks for ID-No: 22078212
MICROMASTER 4, SINAMICS G120 & SINAMICS G120D

Warranty, liability and support

We do not accept any liability for the information contained in this document.
Any claims against us - based on whatever legal reason - resulting from the use of
the examples, information, programs, engineering and performance data etc.,
described in this Application Examples shall be excluded. Such an exclusion shall
not apply in the case of mandatory liability, e.g. under the German Product Liability
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above provisions does not imply a change in the burden of proof to your detriment.
Copyright© 2008 Siemens A&D. It is not permissible to transfer or copy these
Application Examples or excerpts of them without first having prior
Copyright © Siemens AG 2008 All rights reserved

authorization from Siemens A&D in writing.

If you have any recommendations relating to this document then please send them
MainContactorControl_en_V1_4.doc

to us at the following e-mail address:

mailto:[email protected]

Version 1.4 Issue December 2010 3/28

 Preposition

Controlling the main contactor by using free function blocks for ID-No: 22078212
MICROMASTER 4, SINAMICS G120 & SINAMICS G120D

Preposition
Aim of the application
A circuit is described in this application that allows the drive inverter itself to close
the main contactor and automatically enable operation of the drive inverter.

Scope
No additional control equipment is necessary in the form of external components
that ensure the correct sequencing.

Exclusion
This application does not provide a description of
• Basic commissioning of the drive inverter
• Commissioning higher-level controls
It is assumed that the reader has basic knowledge of these subjects.
Copyright © Siemens AG 2008 All rights reserved

The solution can be used for:

MainContactorControl_en_V1_4.doc

• MICROMASTER MM430
• MICROMASTER MM440
• SINAMICS G120 with Control Units CU240…
• SINAMICS G120D with Control Units CU240…

The drive inverter must be supplied from an external 24V power supply:
• MICROMASTER 4 via MICROMASTER Profibus Module
• SINAMICS G120 via terminals 31 and 32 of the Control Unit
• SINAMICS G120D via the logical 24V supply (IN) of the Control Unit

Reference to the Automation and Drives Service & Support

This article is from the Internet Application Portal of the Automation and Drives
Service & Support. You can go directly to the download page of this document
using this link.
http://support.automation.siemens.com/WW/view/en/22078212

Version 1.4 Issue December 2010 4/28

 Application description
Table of Contents

Controlling the main contactor by using free function blocks for ID-No: 22078212
MICROMASTER 4, SINAMICS G120 & SINAMICS G120D

Table of Contents
Table of Contents ................................................................................................ 5
Application description ............................................................................................... 6
1 Task solution ........................................................................................ 6
2 Commissioning..................................................................................... 8
2.1 Main contactor CLOSE command........................................................ 8
2.2 Feedback signal from the main contactor ............................................ 9
2.3 ON command for the frequency inverter ............................................ 10
2.4 OFF command for the frequency inverter .......................................... 10
2.5 OPEN command for the main contactor ............................................ 10
2.6 Sequence of the power-on / power-off sequence for main contactor
control................................................................................................. 11
2.6.1 Sequence of the power-on / power-off sequence for main contactor
control for MICROMASTER 440/430 ................................................. 11
2.6.2 Sequence of the power-on / power-off sequence for main contactor
control for SINAMICS G120 and SINAMICS G120D ......................... 12
2.7 Parameter settings: ............................................................................ 13
Copyright © Siemens AG 2008 All rights reserved

2.8 Connection of the terminals ............................................................... 16

2.9 Connection of the free blocks............................................................. 20
MainContactorControl_en_V1_4.doc

3 Executing scripts in STARTER .......................................................... 22

Appendix and references .......................................................................................... 25
4 Further notes, tips and tricks.............................................................. 25
Influence of high-frequency load currents on the main current path of
the contactor ....................................................................... 25
4.1.1 Selection table for main contactors“................................................... 27
4.2 Internet link data................................................................................. 28
4.3 History ................................................................................................ 28

Version 1.4 Issue December 2010 5/28

 Application description
Task solution

Controlling the main contactor by using free function blocks for ID-No: 22078212
MICROMASTER 4, SINAMICS G120 & SINAMICS G120D

Application description
Contents
MICROMASTER 4, SINAMICS G120 and SINAMICS G120D drive inverters are
designed to be directly connected to the line supply - i.e. a main contactor is not
required. However, for several applications main or input contactors are required.
A circuit is described in this application that offers the drive inverter the following
possibilities:
• The drive inverter itself can close the main contactor
• Operation of the drive inverter is automatically enabled

1 Task solution
The circuit is implemented using free function blocks (FFBs).
This means that there is no additional control expenditure in the form of external
components - that would be necessary in order to ensure the correct sequencing.
Copyright © Siemens AG 2008 All rights reserved

Correct operation requires an external 24V DC power supply for the drive inverter:
MainContactorControl_en_V1_4.doc

• MICROMASTER 4 via MICROMASTER Profibus Module

• SINAMICS G120 via terminals 31 and 32 of the Control Unit
• SINAMICS G120D via the logical 24V supply (IN) of the Control Unit

This solution can be used for:

• MICROMASTER MM430
• MICROMASTER MM440
• SINAMICS G120 with Control Units CU240…
• SINAMICS G120D with Control Units CU240…

Version 1.4 Issue December 2010 6/28

 Application description
Task solution

Controlling the main contactor by using free function blocks for ID-No: 22078212
MICROMASTER 4, SINAMICS G120 & SINAMICS G120D
Copyright © Siemens AG 2008 All rights reserved
MainContactorControl_en_V1_4.doc

Figure 1-1 System overview, main contactor ON / OFF

Note:
Please ensure that all of the contactors in the electrical cabinet are equipped with
noise suppression devices.
AC contactors are equipped with RC suppression devices.
DC contactors are equipped with “free-wheeling” diodes.

Version 1.4 Issue December 2010 7/28

 Application description
Commissioning

Controlling the main contactor by using free function blocks for ID-No: 22078212
MICROMASTER 4, SINAMICS G120 & SINAMICS G120D

2 Commissioning
2.1 Main contactor CLOSE command
The main contactor (CLOSE command) can be controlled from any command
source. The user defines the command source (set P0700).
Possible command sources for MM4:
• BOP (keypad)
• Digital input, e.g. DI1
• USS at the BOP link
• USS at the COM link
• PROFIBUS

Possible command sources for SINAMICS G120 and SINAMICS G120D:

• BOP (keypad)
Copyright © Siemens AG 2008 All rights reserved

• Digital input, e.g. DI0

MainContactorControl_en_V1_4.doc

• PROFINET
• USS at the BOP link
• USS at the COM link
• PROFIBUS

From the selected command source, the user activates the independent contactor
closing. In so doing, flip-flop RS-FF1 is set.
The RS-FF1 output signal energizes the main contactor via the main contactor
relay. For MM4 this is via the digital output DO1 and for the frequency inverters
G120 and G120D via DO0.

Version 1.4 Issue December 2010 8/28

 Application description
Commissioning

Controlling the main contactor by using free function blocks for ID-No: 22078212
MICROMASTER 4, SINAMICS G120 & SINAMICS G120D

2.2 Feedback signal from the main contactor

The power-on operation must be monitored in order to avoid a possible fault
message from the drive inverter caused by the contactor (~ 40 – 100ms switching
delay).
There are two versions of this monitoring function that will now be described in the
following.
The circuits are implemented using free function blocks (FFBs).

Version a) Feedback signal contact

The "ON signal" is evaluated using the feedback signal contact of the main
contactor that is connected to digital input DI2 for MM4 / DI1 for G120 and G120D
> P2812[1] = 722.1 (set P0702 = 99 – BiCo).

Version b) DC link voltage comparison

By comparing the DC link voltage with a specific value the drive inverter is only
powered-up if the drive unit has been pre-charged (Fig. 2-1). This prevents the
Copyright © Siemens AG 2008 All rights reserved

drive unit from being prematurely enabled - that would result in a fault trip. In the
example, the numerical value for the DC link voltage comparator P2889 is for a
MainContactorControl_en_V1_4.doc

drive inverter with an input voltage of 3-ph. 400 V AC. For other line supply
conditions, parameter P2889 must be adapted as follows depending on the
reference voltage P2001:
• 230 V, 1 AC~: P2889 = ~ 28 % of P2001 = 1000 V
• 400 V, 3 AC ~: P2889 = ~ 48 % of P2001 = 1000 V
• 500 V, 3 AC~: P2889 = ~ 60 % of P2001 = 1000 V

Figure 2-1 Comparison of the DC link voltage - main contactor control

Depending on this comparator element or the feedback signal contact the inverter
is enabled or the ON/OFF1 command is enabled.

Version 1.4 Issue December 2010 9/28

 Application description
Commissioning

Controlling the main contactor by using free function blocks for ID-No: 22078212
MICROMASTER 4, SINAMICS G120 & SINAMICS G120D

2.3 ON command for the frequency inverter

The frequency inverter is started if the main contactor has been closed via
DO1/DO0 and the feedback signal from the main contactor has been received.

2.4 OFF command for the frequency inverter

When powering-down (OFF), the inverse sequence applies. When the OFF
command is issued (command source = 0), the frequency inverter is ramped-down
to standstill (zero speed); the main contactor is then opened.

2.5 OPEN command for the main contactor

The status signal "Operation" r0052 bit02 for MM440 and "Ready for operation"
r0052 bit01 for G120 and G120D are delayed by timer 1 and resets flip-flop RS-
Copyright © Siemens AG 2008 All rights reserved

FF1.
MainContactorControl_en_V1_4.doc

The RS-FF1 output signal opens the main contactor via the main contactor relay.
For MM4 frequency inverters this is via digital output DO1 and for G120 and
G120D via DO0.
Instead of the status signals r0052 bit02 for MM4 and r0052 bit01 for G120 and
G120D, the status signal "f_act > P2167 (f_off)" r0053 bit01 can be used together
with the setting "Shutdown frequency f_off" P2167 = 0 Hz for all frequency
inverters.

Version 1.4 Issue December 2010 10/28

 Application description
Commissioning

Controlling the main contactor by using free function blocks for ID-No: 22078212
MICROMASTER 4, SINAMICS G120 & SINAMICS G120D

2.6 Sequence of the power-on / power-off sequence for

main contactor control
2.6.1 Sequence of the power-on / power-off sequence for main contactor
control for MICROMASTER 440/430

ON/OFF1 via:
BOP, DI1, USS or 1
PROFIBUS
t
0
Main contactor ON/OFF:
DO1 1

t
0
Copyright © Siemens AG 2008 All rights reserved

ON/OFF1
Cont.Wrd.1 r0054.0 1
MainContactorControl_en_V1_4.doc

t
0
Drive running r0052.2 or
f_act > 2167 (f_off) r0053.1 1
with P2167 = 0 Hz
t
0
RFG active Ramp-up along RFG
1

t
0
Ramp-down along RFG

Figure 2-2 Sequence of the power-on / power-off sequence for main contactor control for
MICROMASTER 440/430

Version 1.4 Issue December 2010 11/28

 Application description
Commissioning

Controlling the main contactor by using free function blocks for ID-No: 22078212
MICROMASTER 4, SINAMICS G120 & SINAMICS G120D

2.6.2 Sequence of the power-on / power-off sequence for main contactor

control for SINAMICS G120 and SINAMICS G120D
Copyright © Siemens AG 2008 All rights reserved
MainContactorControl_en_V1_4.doc

Figure 2-3 Sequence of the power-on / power-off sequence for main contactor control for
SINAMICS G120 and SINAMICS G120D

Version 1.4 Issue December 2010 12/28

 Application description
Commissioning

Controlling the main contactor by using free function blocks for ID-No: 22078212
MICROMASTER 4, SINAMICS G120 & SINAMICS G120D

2.7 Parameter settings:

Table 2-1 Parameter settings

Parameter Designation Parameter value Note / comments
No.
P0700[0] Selection of command source ?* Select the source for the ON command for
the main contactor:
1: BOP (keypad)
2: Terminal
4: USS on BOP link
5: USS on COM link
6: PROFIBUS or PROFINET (only for
CU240S/D PN/PN-F)
P0701[0] MM4: Digital input 1 (DI1) 99 Enable BICO parameterization, only if
CU240: Digital input 0 (DI0) P0700 = 2
P0702[0] MM4: Digital input 2 (DI2) 99 Enable BICO parameterization, only if the
Copyright © Siemens AG 2008 All rights reserved

CU240: Digital input 1 (DI1) feedback from the feedback contact of the
main contactor is selected
MainContactorControl_en_V1_4.doc

P0922 Selection of PROFIdrive 999 Free BICO connection, only for CU240
Standard Telegram
P0731[0] MM4: Digital output 1 (DO1) r2841.0 MM4: DO1 = RS-FF1 output
CU240: Digital output 0 CU240 DO0 = RS-FF1 output
(DO0)
P0840[0] BI: ON/OFF 1 r2815.0 Enable ON/OFF1 = Output AND 3
P0852[0] BI: Pulse enable r2813.0 Pulse enable = output AND 2
P1000[0] Selection of frequency ? Set frequency setpoint:
setpoint 1: MOP setpoint
2: Analog setpoint
3: Fixed frequency
4: USS on BOP link
5: USS on COM link
6: CB on COM link

*
? = Plant dependent, not relevant

Version 1.4 Issue December 2010 13/28

 Application description
Commissioning

Controlling the main contactor by using free function blocks for ID-No: 22078212
MICROMASTER 4, SINAMICS G120 & SINAMICS G120D

Parameter Designation Parameter value Note / comments

No.
P2150[0] Hysteresis, f1 threshold 0.5 Hz Hysteresis, f1 threshold
P2155[0] f1 threshold 1 Hz Frequency threshold 1
P2800 Enable FFB 1 1 = FFB enabled
P2801[0] Activate AND 1 1 1 = AND 1 at level 1
P2801[1] Activate AND 2 1 1 = AND 2 at level 1
P2801[2] Activate AND 3 1 1 = AND 3 at level 1
P2801[14] Activate RS-FF 1 1 RS-FF 1 at level 1
P2802[0] Activate timer 1 1 1 = timer 1 at level 1
P2802[12] Activate CMP 1 1 1 = CMP 1 at level 1
P2810[0] BI: AND 1 index 0 r2852.0 AND 1 index 0 = Output timer 1
P2810[1] BI: AND 1 index 1 r0053.5 AND 1 index 0 =
Copyright © Siemens AG 2008 All rights reserved

r0053.5 fact <= P2155

MainContactorControl_en_V1_4.doc

P2812[0] BI: AND 2 index 0 r2841.0 AND 2 index 0 = Output RS-FF1

P2812[1] BI: AND 2 index 1 r0722.1 or AND 2 index 1 =
DI2 (MM4) / DI1 (CU240) if feedback
r2886.0
signal contact is selected
or
Output CMP 1 if DC link voltage
comparison is selected.
P2814[0] BI: AND 3 index 0 r2813.0 AND 3 index 0 = Output AND 2
P2814[1] BI: AND 3 index 1 r0019.0 or AND 3 index 1 =
r0722.0 or r0019.0: BOP
r2032.0 or r0722.0: DI1 (MM4) / DI0 (CU240)
r2036.0 or r2032.0: USS on BOP link
r2090.0 or r2036.0: USS on COM link
r8890.0 r2090.0: PROFIBUS
r8890.0: PROFINET (only for CU240S/D
PN/PN-F)

Version 1.4 Issue December 2010 14/28

 Application description
Commissioning

Controlling the main contactor by using free function blocks for ID-No: 22078212
MICROMASTER 4, SINAMICS G120 & SINAMICS G120D

Parameter Designation Parameter value Note / comments

No.
P2840[0] BI: RS-FF1 index 0 r0019.0 or RS-FF1 index 0 =
r0722.0 or r0019.0: BOP
r2032.0 or r0722.0: DI1 (MM4) / DI0 (CU240)
r2036.0 or r2032.0: USS on BOP link
r2090.0 or r2036.0: USS on COM link
r8890.0 r2090.0: PROFIBUS
r8890.0: PROFINET (only for
CU240S/D PN/PN-F)
P2840[1] BI: RS-FF1 index 1 r2811.0 RS-FF1 index 1 = Output AND 1
P2849 BI : Timer 1 MM4: r0052.2 or MM4: Status word 1: Drive running or
r0053.1 + P2167 Status word 2: f_act > P2167 (f_off) +
= 0 Hz Switch-off frequency f_off P2167 = 0 Hz
CU240: r0052.1 CU240: Status word 1: Drive ready to run
or r0053.1 + or Status word 2: f_act > P2167 (f_off) +
P2167 = 0 Hz Switch-off frequency f_off P2167 = 0 Hz
P2850 Delay of timer 1 0.5 s Delay time = 0.5 seconds
Copyright © Siemens AG 2008 All rights reserved

P2851 Timer mode 2 Power-on/power-off delay

MainContactorControl_en_V1_4.doc

P2885[0] BI: CMP 1 index 0 MM4: r0026 CMP 1 index 0 =

CU240: r0026.0 Absolute value VDC link
P2885[1] BI: CMP 1 index 1 P2889 CMP 1 index 1 = Fixed connector 1
P2889 Fixed connector 1 48 % Fixed connector 1 = % of P2001
reference voltage:
230 V, 1 AC: = ~ 28%
400 V, 3 AC: = ~ 48%
500 V, 3 AC: = ~ 60%

Version 1.4 Issue December 2010 15/28

 Copyright © Siemens AG 2008 All rights reserved
MainContactorControl_en_V1_4.doc

Application description
Commissioning

Controlling the main contactor by using free function blocks for MICROMASTER 4, SINAMICS G120 & SINAMICS G120D ID-No: 22078212

2.8 Connection of the terminals

L1
L2 1) This is the simplified representation of the logic configured in
L3
PE the frequency inverter. All of the interconnections between the
free function blocks for MM430/MM440 are shown in Fig. 2-8.
24V external
- +
2) The (–) terminal 2 of the power supply of the PROFIBUS
MICROMASTER 430/440
module is at the same potential as the insulated 0V terminal 28
Connection of the free blocks 1) K1 of the MM430/440.
Main contactor ON via: Main contactor ON/OFF via DO1
3) Terminal 9 of the MM430/MM40 can be used for the power
BOP
Digital input DI1
r0019.0
r0722.0 Q r2841
P0731[0]
r2841
supply of digital inputs DI1 and DI2, if the max. current demand

L1

L2

L3
PE
USS on BOP link
USS on COM link
r2032.0
r2036.0 R AC does not exceed 100 mA.
PROFIBUS r2090.0
ON command DC
& for drive
Main contactor OFF via:
St.Wrd.1 Bit02 r0052.2 Drive ON/OFF
St.Wrd.2 Bit01 r0053.1 OFF command for drive:
P0840[0]
MICROMASTER
BOP
Digital input DI1
r0019.0 & r2815 r2815
r0722.0
PROFIBUS Feedback from the main USS on BOP link r2032.0
Module contactor: DI2 USS on COM link r2036.0
r0722.1 PROFIBUS r2090.0
Pre-charge finished r2886

DO1

2) DC

COM
NO
+24V

0V

NC
DI1
DI2

AC
+24V
0V

PE

PE
1 2 5 6 9 28 20 1918

W
U

V
24V external
3)
U V W PE
Main contactor Feedback signal K1 to DI2
ON via DI1 M
3~

Figure 2-4 Controlling the main contactor for MICROMASTER 430/440 via DO1: connection of the terminals

Version 1.4 Issue December 2010 16/28

 Copyright © Siemens AG 2008 All rights reserved
MainContactorControl_en_V1_4.doc

Application description
Commissioning

Controlling the main contactor by using free function blocks for MICROMASTER 4, SINAMICS G120 & SINAMICS G120D ID-No: 22078212

4) This is the simplified representation of the logic configured in

the frequency inverter. All of the interconnections of the free
function blocks for SINAMICS G120 / SINAMICS G120D are
shown in Fig. 2-9.

5) Terminal 9 of the CU240 … Control Unit can be used for the

4) power supply of the digital inputs DI0 and DI1, if the max.
current demand does not exceed 100 mA.

L1

L2

L3
PE
+24V

0V

COM
NO
NC
0V
+24V

DI0
DI1

PE

PE
W
U

V
5)

Figure 2-5 Controlling the main contactor for SINAMICS G120 via DO0: connection of the terminals

Version 1.4 Issue December 2010 17/28

 Copyright © Siemens AG 2008 All rights reserved
MainContactorControl_en_V1_4.doc

Application description
Commissioning

Controlling the main contactor by using free function blocks for MICROMASTER 4, SINAMICS G120 & SINAMICS G120D ID-No: 22078212
L1
L2
L3 6) The non-switched and switched 24 V supply are provided
PE
using appropriate external sources.
24V external6)
switched
The non-switched 24 V supply is designed to provided
SINAMICS G120D - + permanent power to the internal control electronics, the power
module electronics, the digital inputs and the encoder input.
Control Unit CU240D...
The switched 24 V supply is provided to power only the digital
K1 outputs - these outputs are isolated from the rest of the drive
Connection of the free blocks 7)
electronics. This configuration allows the digital outputs to be
Main contactor ON via: Main contactor ON/OFF via DO0
HAN Q4/2 L1 L2 L3 PE switched on or off without disrupting the normal functioning of
BOP r0019.0 P0731[0] the Inverter.
Digital input DI0 1 2 3 4 11 12 PE
PROFINET
r0722.0
r8890.0
Q r2841 r2841
Power If it is not necessary to disconnect the 24 V supply then the
USS on BOP link
USS on COM link
r2032.0 R Module Line filter switched as well as also the non-switched 24 V can be taken
r2036.0
PROFIBUS r2090.0 ON command PM250D class A from the same supply (you can connect cable conductors "0 V
& for drive switched" with "0 V non-switched" and "+24 V switched" with
AC
Main contactor OFF via: DC "+24 V non-switched" - refer to Fig. 2-7).
St.Wrd.1 Bit01 r0052.1 Drive ON/OFF
St.Wrd.2 Bit01 r0053.1
OFF command for drive:
P0840[0]
7) This is the simplified representation of the logic configured
BOP r0019.0 & r2815 r2815 in the frequency inverter. All of the interconnections of free
Digital input DI0 r0722.0
Feedback from the main PROFINET r8890.0 function blocks for SINAMICS G120 / SINAMICS G120D are
contactor: DI1 USS on BOP link r2032.0 shown in Fig. 2-9.
r0722.1 USS on COM link r2036.0
Pre-charge finished r2886 PROFIBUS r2090.0
DO0

DC
AC

DO0
DI0
DI1

PE PE
4 2 3 5 1 4 2 1 3 5 1 2 3 4 5 5 8 4 6 2 PE 1 7 3

7/8" – 16UN 24V 0V PE 24V 0V PE U V W

HAN Q8
DI0 DI1 24V 0V PE M12 – 5 pole M12 – 5 pole DO1 0V DO0 PE
24V external (IN) DI0, DI1 DO0, DO1
Main contactor

Feedback signal K1
ON via DI0

M
to DI1

3~

6)
24V external
non-switched + -

Figure 2-6 Controlling the main contactor for SINAMICS G120 via DO0: connection of the terminals; 24 V supply using switched and non-switched external sources

Version 1.4 Issue December 2010 18/28

 Copyright © Siemens AG 2008 All rights reserved
MainContactorControl_en_V1_4.doc

Application description
Commissioning

Controlling the main contactor by using free function blocks for MICROMASTER 4, SINAMICS G120 & SINAMICS G120D ID-No: 22078212
L1
L2
L3
8) This is the simplified representation of the logic
PE configured in the frequency inverter. All of the
24V external interconnections between free function blocks for
non-switched SINAMICS G120 / SINAMICS G120D are shown in
SINAMICS G120D - +
Fig. 2-9.
Control Unit CU240D...

Connection of the free blocks 8) K1

Main contactor ON via: Main contactor ON/OFF via DO0 L1 L2 L3 PE

HAN Q4/2
BOP r0019.0 P0731[0]
Digital input DI0 1 2 3 4 11 12 PE
r0722.0 Q r2841 r2841
PROFINET r8890.0 Power
R
USS on BOP link
USS on COM link
r2032.0
r2036.0
Module Line filter
PROFIBUS r2090.0 ON command PM250D class A
& for drive
AC
Main contactor OFF via: DC
St.Wrd.1 Bit01 r0052.1 Drive ON/OFF
St.Wrd.2 Bit01 r0053.1
OFF command for drive:
P0840[0]
BOP
Digital input DI0
r0019.0 & r2815 r2815
r0722.0
Feedback from the main PROFINET r8890.0
contactor: DI1 USS on BOP link r2032.0
r0722.1 USS on COM link r2036.0
Pre-charge finished r2886 PROFIBUS r2090.0
DO0

DC
AC

DO0
DI0
DI1

PE PE
4 2 3 5 1 4 2 1 3 5 1 2 3 4 5 5 8 4 6 2 PE 1 7 3

7/8" – 16UN 24V 0V PE 24V 0V PE U V W

DI0 DI1 24V 0V PE M12 – 5 pole M12 – 5 pole DO1 0V DO0 PE HAN Q8
24V external (IN) DI0, DI1 DO0, DO1
Feedback signal K1
Main contactor
ON via DI0

M
to DI1

3~

Figure 2-7 Controlling the main contactor for SINAMICS G120 via DO0: connection of the terminals; 24 V supply using only a non-switched external source

Version 1.4 Issue December 2010 19/28

 Copyright © Siemens AG 2008 All rights reserved
MainContactorControl_en_V1_4.doc

Application description
Commissioning

Controlling the main contactor by using free function blocks for MICROMASTER 4, SINAMICS G120 & SINAMICS G120D ID-No: 22078212

2.9 Connection of the free blocks

9) 9) A source should be selected for the CLOSE command
of the main contactor, e.g. digital input DI1: P0700 = 2.

10) As OPEN command for the main contactor, either

the status signal ZSW1 bit02 Operation or ZSW2 bit01
f_act > P2167 with P2167 = 0 Hz can be selected.

11) Either the signal from the feedback signal contact of

10)
the main contactor can be used as feedback signal or
the signal from the CMP1 "Pre-charging completed".

12) The frequency inverter is started if the main

contactor has been closed via DO1 and the feedback
signal has been received from the main contactor.
13) When powering-down, the inverse sequence applies.
When the OFF command is issued (command source =
0) the frequency inverter ramps down to standstill (zero
speed) and then the main contactor is opened.

11)

12)

13)

Figure 2-8 Controlling the main contactor for MICROMASTER 430/440 via DO1: connection of the free blocks

Version 1.4 Issue December 2010 20/28

 Copyright © Siemens AG 2008 All rights reserved
MainContactorControl_en_V1_4.doc

Application description
Commissioning

Controlling the main contactor by using free function blocks for MICROMASTER 4, SINAMICS G120 & SINAMICS G120D ID-No: 22078212

14)
14) A source should be selected for the CLOSE
command of the main contactor, e.g. digital input DI0:
P0700 = 2.

15) Either the status signal ZSW1 bit01 ready for

operation or ZSW2 bit01 f_act > P2167 with P2167 = 0
Hz should be selected for the OPEN command.
15)
16) Either the signal from the feedback signal contact of
the main contactor or the signal from the CMP1 "Pre-
charging completed" can be selected as feedback signal
from the main contactor.

17) The frequency inverter is started if the main

contactor has been closed via DO0 and the feedback
signal has been received from the main contactor.
18) When powering-down the inverse sequence applies.
When the OFF command is issued (command source =
0), the frequency inverter ramps down to standstill (zero
speed) and then the main contactor is opened.

16)

17)

18)

Figure 2-9 Controlling the main contactor for SINAMICS G120 and SINAMICS G120D via DO0: connection of the free blocks

Version 1.4 Issue December 2010 21/28

 Application description
Executing scripts in STARTER

Controlling the main contactor by using free function blocks for ID-No: 22078212
MICROMASTER 4, SINAMICS G120 & SINAMICS G120D

3 Executing scripts in STARTER

For fast parameter changes, you can use the attached script files (for CU240 and
MM4).
Note:
Before you use the corresponding script, please set your drive inverter to the
factory settings (P0010 = 30, P0970 = 1).

The procedure in detail:

1. Save the attached script file in a folder on your computer hard drive.

2. Set-up a script folder for the drive in your STARTER project by clicking with the
righthand mouse key on the drive; then click on "Expert" (lefthand mouse key)
and on "Insert script folder".
Copyright © Siemens AG 2008 All rights reserved

A new folder appears "SCRIPTS" at the lower end of the tree

MainContactorControl_en_V1_4.doc

3. Import the script from your folder into STARTER as described below:
– Using the righthand mouse key click on the tab "SCRIPTS";
– Click on "ASCII import..." and open the required script file;
– Assign a name to the opened file and acknowledge with OK.

Version 1.4 Issue December 2010 22/28

 Application description
Executing scripts in STARTER

Controlling the main contactor by using free function blocks for ID-No: 22078212
MICROMASTER 4, SINAMICS G120 & SINAMICS G120D

4. Execute the script by clicking with the righthand mouse key on the script and
clicking "Accept and execute";

or open the script by double clicking on it and then pressing the button
"Accept and execute".
Also refer to Entry ID: 32582476

5. Im ersten Fenster wählen Sie die Quelle für den EIN-Befehl für das
Hauptschütz aus. Geben Sie eine Zahl von 1 bis 6 für CU240 oder 1, 2, 4, 5, 6
für MM4 ein (die möglichen Einstellungen sind auf der Abbildung 3-1 zu sehen)
und drücken Sie auf den Button „OK“.

CU240: MM4:
Copyright © Siemens AG 2008 All rights reserved
MainContactorControl_en_V1_4.doc

Figure 3-1 Selecting the source for the main contactor CLOSE command

6. In the second window, select the source of the main setpoint. Enter a number
of between 1 and 6 (the possible settings can be seen in Fig. 3-2) and press on
the "OK" button.

Figure 3-2 Selects the main setpoint source

Version 1.4 Issue December 2010 23/28

 Application description
Executing scripts in STARTER

Controlling the main contactor by using free function blocks for ID-No: 22078212
MICROMASTER 4, SINAMICS G120 & SINAMICS G120D

7. In the third window, select the source of the feedback signal. Either enter 1
(feedback signal contact) or 2 (DC link voltage comparison) and press on the
"OK" button.

Figure 3-3 Selecting the source of the feedback signal

8. If you have selected the DC voltage comparison as feedback signal from the
main contactor, then the next window opens in which you should select the line
supply voltage. Enter a 1 (230V, 1 AC~), 2 (400V, 3 AC~) or 3 (500V, 3 AC~)
and then press the "OK" button.
Copyright © Siemens AG 2008 All rights reserved
MainContactorControl_en_V1_4.doc

Figure 3-4 Selecting the line supply voltage

STARTER then writes all of the parameters required for parameterization into the
frequency inverter. After the script has been run the following message is output
"Script run completed".

Version 1.4 Issue December 2010 24/28

 Appendix and references
Further notes, tips and tricks

Controlling the main contactor by using free function blocks for ID-No: 22078212
MICROMASTER 4, SINAMICS G120 & SINAMICS G120D

Appendix and references

4 Further notes, tips and tricks

When using contactors in front of drive inverters with a pulsed voltage, there are
effects that can result in an increased temperature rise of the main contactor
contacts or failure of the contactor operating mechanism (solenoid coil). We
therefore generally recommend that the contactor should not be dimensioned
according to AC1 (non-inductive or weak inductive load, resistance ovens).
Practical engineering information for applications such as these is provided in the
following.

Influence of19high-frequency load currents on the main current path of the contactor
Motor currents with a higher basic frequency (> 50/60 Hz) result in higher losses
and therefore an increased temperature rise. The reason for this is the skin effect
and the formation of eddy currents in electrically conductive materials.
Copyright © Siemens AG 2008 All rights reserved

This additional temperature rise depends on the particular base frequency and the
MainContactorControl_en_V1_4.doc

harmonic component of the current. As an additional factor, at the secondary side

of drive inverters capacitive discharge currents can flow with respect to ground
potential or through capacitor circuits when filters are used. These must also be
taken into account when dimensioning the contactors.
When switching capacitances (DC link capacitors or filters) the capability of the
contactors in switching capacitors must also be taken into account.
Frequency combinations must be geometrically added using their component of the
particular frequency and the corresponding derating factor.
As an alternative, a de-rating factor of 0.8 should be used selecting/dimensioning
the contactor - this is a value gained from experience in the field. This safety factor
should be multiplied by the derating factor for the base frequency according to the
contactor characteristics.

19
Excerpt from the information sheet "Using switching devices in drive inverter systems"

Version 1.4 Issue December 2010 25/28

 Appendix and references
Further notes, tips and tricks

Controlling the main contactor by using free function blocks for ID-No: 22078212
MICROMASTER 4, SINAMICS G120 & SINAMICS G120D

Example
A Size S6 contactor with frame-type terminals should be able to conduct the
following current with a harmonic content (Table 135,51A).

Table 4-1 Calculation example for Size S6 contactor

Order No. of the harmonic 1 5 7 11 13 15
(1 = basic fundamental) 50Hz 250Hz 350Hz 550Hz 650Hz 750Hz
Per unit (PU) value of the current harmonic
referred to the basic fundamental 100.0 72.5 52.6 17.0 7.2 0.0
[%]
rms values of the individual oscillations
(as example, basic fundamental with 100A) 100.0 72.5 52.6 17.0 7.2 0.0
[A]
rms value of the total current
(geom. addition) 135.51 Irms= (100)2 + (72,5)2 + (52,6)2 + (17.
..0)2 + (7..2)2
[A]
Derating factor depending on the harmonic
1 0.725 0.675 0.620 0.600 0.575
corresponding to diagram 1 for S6
Copyright © Siemens AG 2008 All rights reserved

Current of the particular harmonic

MainContactorControl_en_V1_4.doc

multiplied with its associated derating factor 100.0 52.6 35.5 10.5 4.3 0.0
[A]
Reduced permissible rms value of this
total current for the selected frame size
(geom. addition)
118.97 Irms= (100)2 + (52,6)2 + (35,5)2 + (10,.5)2 + (4,3) 2
[A]

Resulting derating factor for the max. rated.

118 , 97 A
current of the selected frame size 0.878 k derating =
135 , 51 A
(in this example, S6)

For this particular example, a 3RT1055... (S6, 75 kW, 150 A rated current) is not
sufficient as according to the calculation 150 A x 0.878 results in 131.70 A.
The rms value of the total current in this example is 135.51 A and is therefore
above the calculated, permissible rated current of 131.70 A.
The 3RT1056... (S6, 90 kW, 185 A rated current) has, for this application, a
calculated, permissible rated current of 185 A x 0.878 = 162.43 A - and can
therefore conduct a total current of 135.51 A.
In this application case the permissible operating current of the contactor is
reduced to 87.8% (referred to the specified rated operating current)!
Information and tables regarding the input currents and fuses for MICROMASTER
4 are provided in Catalog DA51.2, for SINAMICS G120 – in Catalog D11.1 or in the
Operating Instructions (Chapter, Technical data) of the particular drive inverter.

Version 1.4 Issue December 2010 26/28

 Appendix and references
Further notes, tips and tricks

Controlling the main contactor by using free function blocks for ID-No: 22078212
MICROMASTER 4, SINAMICS G120 & SINAMICS G120D

4.1.1 Selection table for main contactors“

Table 4-2
Rated current Order number Rated
[A] MLFB load / voltage
8 3RT1015 3KW/400V
22 3RT1016 4KW/400V
40 3RT1025 7,5KW/400V
50 3RT1034 15KW/400V
60 3RT1035 18,5KW/400V
100 3RT1044 30KW/400V
120 3RT1045 37KW/400V
140 3RT1046 45KW/400V
185 3RT1055 75KW/400V
Copyright © Siemens AG 2008 All rights reserved

215 3RT1056 90KW/400V

MainContactorControl_en_V1_4.doc

275 3RT1064 110KW/400V

330 3RT1065 132KW/400V
430 3RT1075 200KW/400V
610 3RT1076 250KW/400V

Further information pleasefind at: „Industrial Controls SIRIUS“

Version 1.4 Issue December 2010 27/28

 Appendix and references
Further notes, tips and tricks

Controlling the main contactor by using free function blocks for ID-No: 22078212
MICROMASTER 4, SINAMICS G120 & SINAMICS G120D

4.2 Internet link data

This list is in no way complete and only reflects a selection of suitable references.

Table 4-3
Subject area Title
\1\ Catalogs [INTRANET] DA51.2, D11.1
\2\ Manual MM440
\3\ Manual MM430
\4\ Manual SINAMISC G120
\5\ Manual SINAMICS G120D
\6\ FAQ How can I transfer projects from DriveMonitor into
STARTER?
\7\ FAQ Using the external 24 V power supply at the
MICROMASTER 4 Profibus Module
\8\ FAQ Cascading the 24 Volt power supply of the
Copyright © Siemens AG 2008 All rights reserved

CU240D
MainContactorControl_en_V1_4.doc

4.3 History
Table 4-4 History
Version Datum Change
V1 March 2003 First edition
V1.1 November 2005 Design revised
V1.2 September 2007 Text and figures revised, chapter "Further notes..."
inserted.
V1.3 February 2008 Text and figures revised, scripts written, chapter
“Executing scripts in STARTER” inserted.
1.4 December 2010 Chapter 4.1.1 new

Version 1.4 Issue December 2010 28/28