DAY 01
Softwell SINAMICS G120 — Handwritten M-Step Manual
Connection & First Commissioning
Practical Outcome: Connect SIMATIC STARTER V5.7 with SINAMICS G120 via USB/Ethernet, upload parameters, compare online/offline and complete quick commissioning.
Trainer Note: Complete every step in SIMATIC STARTER V5.7 with safe wiring, correct parameter backup, online monitoring and final commissioning checklist.
01
Step 1. Install / connect USB PC Adapter A2 or Ethernet cable to CU240E-2 / CU240E-2-PN.
02
Step 2. Open STARTER V5.7 and set PG/PC Interface: PC Adapter USB A2 or PN/IE according to connection.
03
Step 3. Create new project: SINAMICS G120, CU240E-2 / CU240E-2-PN, firmware V4.9 or available firmware.
04
Step 4. Use Accessible Nodes / Connect to target system and confirm drive appears online.
05
Step 5. Upload all parameters from drive to PC using Load to PG/PC and save project backup.
06
Step 6. Compare online/offline parameters and note any differences before changing drive settings.
07
Step 7. Run Quick Commissioning Wizard and enter motor nameplate data: voltage, current, kW, cos phi, Hz and RPM.
08
Step 8. Select control mode, application class, command source and ramp-up/ramp-down time.
09
Step 9. Perform Motor Data Identification Run after mechanical safety check.
10
Step 10. Save parameters to EEPROM using p0971 = 1 and archive final commissioned project.
Parameter / Wiring Reference
p0010 = 30 // Factory reset preparation p0970 = 1 // Factory reset p0304 = 400 // Rated motor voltage p0305 = 2.05// Rated motor current p0307 = 0.75// Rated motor power p0310 = 50 // Rated frequency p0311 = 1395// Rated speed p0971 = 1 // Save RAM to EEPROM
Daily Practice / Viva
Prepare one screenshot or handwritten note for communication setting, parameter list, wiring check, troubleshooting point and final test result of Day 01.
DAY 02
Softwell SINAMICS G120 — Handwritten M-Step Manual
Drive Macros: Fixed Speed & Analog Reference
Practical Outcome: Commission SINAMICS G120 using macro-based control for terminal commands, fixed speeds and analog speed reference.
Trainer Note: Complete every step in SIMATIC STARTER V5.7 with safe wiring, correct parameter backup, online monitoring and final commissioning checklist.
01
Step 1. Open Quick Commissioning and understand drive macros as ready-made command/reference templates.
02
Step 2. Select Macro 1 for simple terminal start/stop with basic speed reference.
03
Step 3. Wire digital input commands as per selected macro and verify DI status in STARTER diagnostics.
04
Step 4. Set minimum and maximum frequency limits such as p1080 and p1082.
05
Step 5. Configure ramp-up p1120 and ramp-down p1121 according to machine requirement.
06
Step 6. Select Macro 3 / fixed speed configuration and assign DI inputs to fixed frequency selection.
07
Step 7. Configure fixed speeds and test each DI combination safely.
08
Step 8. Select Macro 12 for analog reference using AI input.
09
Step 9. Scale 0–10V / 4–20mA analog input and verify r0755 / actual reference value.
10
Step 10. Document macro number, terminal wiring, speed values and final running test result.
Parameter / Wiring Reference
p0015 = 1 // Macro 1 example p1080 = 0.00 // Minimum frequency p1082 = 50.0 // Maximum frequency p1120 = 5.0 // Ramp-up time p1121 = 5.0 // Ramp-down time p1001 = 10.0 // Fixed speed 1 p1002 = 25.0 // Fixed speed 2 p1003 = 40.0 // Fixed speed 3
Daily Practice / Viva
Prepare one screenshot or handwritten note for communication setting, parameter list, wiring check, troubleshooting point and final test result of Day 02.
DAY 03
Softwell SINAMICS G120 — Handwritten M-Step Manual
Macro 7 PROFINET PLC Communication
Practical Outcome: Configure G120 with Compact / Siemens PLC style fieldbus control using PROFINET, telegram, control word, status word and speed reference.
Trainer Note: Complete every step in SIMATIC STARTER V5.7 with safe wiring, correct parameter backup, online monitoring and final commissioning checklist.
01
Step 1. Assign PROFINET device name to CU240E-2-PN and verify exact name in PLC hardware configuration.
02
Step 2. Set IP address, subnet and network connection using Accessible Nodes or STARTER online settings.
03
Step 3. Select Macro 7 / fieldbus control for PROFINET communication.
04
Step 4. Configure telegram 1 or project-specified PROFIdrive telegram.
05
Step 5. Map PLC output words to drive control word and speed setpoint.
06
Step 6. Map drive input words to PLC status word and actual speed feedback.
07
Step 7. Test STW1 bits: ON/OFF1, enable operation, fault acknowledge and direction as per PLC logic.
08
Step 8. Monitor ZSW1 status word to confirm ready, operation enabled, fault and warning status.
09
Step 9. Scale PLC speed setpoint to drive reference and verify actual frequency feedback.
10
Step 10. Save STARTER project and prepare PLC-drive commissioning checklist.
Parameter / Wiring Reference
// Telegram 1 common word mapping PLC -> Drive PZD1 = STW1 Control Word PLC -> Drive PZD2 = Speed Setpoint Drive -> PLC PZD1 = ZSW1 Status Word Drive -> PLC PZD2 = Actual Speed STW1 bit 0 = ON/OFF1 STW1 bit 1 = OFF2 enable STW1 bit 2 = OFF3 enable STW1 bit 7 = Fault acknowledge
Daily Practice / Viva
Prepare one screenshot or handwritten note for communication setting, parameter list, wiring check, troubleshooting point and final test result of Day 03.
DAY 04
Softwell SINAMICS G120 — Handwritten M-Step Manual
Macro 21 Modbus RTU / USS Communication
Practical Outcome: Configure RS485 communication for Modbus RTU or USS and test register-based control, status and speed reference.
Trainer Note: Complete every step in SIMATIC STARTER V5.7 with safe wiring, correct parameter backup, online monitoring and final commissioning checklist.
01
Step 1. Identify CU240E-2 RS485 terminals and prepare shielded twisted pair communication wiring.
02
Step 2. Set slave address, baud rate, parity, stop bits and protocol type according to master device.
03
Step 3. Select Macro 21 for Modbus RTU / USS communication as per training setup.
04
Step 4. Configure command source and speed reference from serial communication.
05
Step 5. Understand Modbus holding registers used for command word, reference and status values.
06
Step 6. Test communication using Modbus master software or PLC Modbus block.
07
Step 7. Write ON command and speed setpoint from master and verify drive response.
08
Step 8. Read actual frequency, current, status word and fault code from drive.
09
Step 9. Troubleshoot no-response errors: A/B polarity, address mismatch, baud/parity mismatch and termination resistor.
10
Step 10. Document final Modbus register map and verified test values.
Parameter / Wiring Reference
// Typical serial settings for lab Protocol = Modbus RTU / USS Slave address = 3 Baud rate = 9600 or 19200 Parity = Even Stop bits = 1 Cable = Shielded twisted pair RS485 Termination = ON at both ends only
Daily Practice / Viva
Prepare one screenshot or handwritten note for communication setting, parameter list, wiring check, troubleshooting point and final test result of Day 04.
DAY 05
Softwell SINAMICS G120 — Handwritten M-Step Manual
Macro 17–20 Two-Wire / Three-Wire Control
Practical Outcome: Commission terminal-based two-wire and three-wire control circuits with safe start/stop, jog, direction, fault reset and final viva.
Trainer Note: Complete every step in SIMATIC STARTER V5.7 with safe wiring, correct parameter backup, online monitoring and final commissioning checklist.
01
Step 1. Explain difference between two-wire maintained command and three-wire momentary start/stop command.
02
Step 2. Select Macro 17 / 18 / 19 / 20 according to required terminal control method.
03
Step 3. Wire start, stop, forward, reverse, jog and fault reset inputs as per macro terminal diagram.
04
Step 4. Check DI status online before enabling motor output.
05
Step 5. Test two-wire command: maintained input ON runs drive, OFF stops drive.
06
Step 6. Test three-wire command: momentary start latches internal run, stop input breaks run command.
07
Step 7. Add direction command and verify reverse operation only if motor/mechanical system allows it.
08
Step 8. Test fault acknowledge input and confirm drive resets only after fault source is clear.
09
Step 9. Prepare final backup, parameter list, wiring checklist and safety checklist.
10
Step 10. Final viva: connection methods, macro selection, motor ID, EEPROM save, control word/status word and troubleshooting.
Parameter / Wiring Reference
// Final handover checklist [ ] Correct macro selected [ ] Motor nameplate data verified [ ] Ramp-up / ramp-down tested [ ] DI/AI wiring checked [ ] PROFINET or Modbus tested if used [ ] Fault reset verified [ ] p0971 = 1 EEPROM save done [ ] STARTER backup archived
Daily Practice / Viva
Prepare one screenshot or handwritten note for communication setting, parameter list, wiring check, troubleshooting point and final test result of Day 05.