Siemens PM250 Assembly instructions

Answers for industry.
SINAMICS
SINAMICS G120
PM250 Power Module
Hardware Installation Manual· 09/2012
Siemens Parts

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SINAMICS
SINAMICS G120
PM250 Power Module
Hardware Installation Manual
Edition 09/2012
09/2012
A5E01003502B AD
Introduction
1
Safety instructions
2
Installing/Mounting
3
Connecting
4
Service and maintenance
5
Technical specifications
6
Accessories
7
Appendix
A
Siemens Parts

Siemens AG
Industry Sector
Postfach 48 48
90026 NÜRNBERG
GERMANY
Ⓟ 09/2012 Technical data subject to change
Copyright © Siemens AG 2006 - 2012.
All rights reserved
Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
indicates that minor personal injury can result if proper precautions are not taken.
NOTICE
indicates that property damage can result if proper precautions are not taken.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
Qualified Personnel
The product/system described in this documentation may be operated only by personnel qualified for the specific
task in accordance with the relevant documentation, in particular its warning notices and safety instructions.
Qualified personnel are those who, based on their training and experience, are capable of identifying risks and
avoiding potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended
or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be complied with. The information in the relevant documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication
may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.

PM250 Power Module
Hardware Installation Manual, 09/2012, A5E01003502B AD 5
Table of contents
1 Introduction................................................................................................................................................ 7
1.1 Power Modules PM250..................................................................................................................8
1.2 Block diagram ................................................................................................................................9
1.3 Documents for the Inverter ..........................................................................................................10
2 Safety instructions ................................................................................................................................... 11
2.1 Residual risks...............................................................................................................................16
3 Installing/Mounting................................................................................................................................... 19
3.1 Installation conditions...................................................................................................................19
3.2 Air cooling requirements ..............................................................................................................20
3.3 Dimensions and drill pattern ........................................................................................................22
3.4 Control Unit installation ................................................................................................................29
4 Connecting .............................................................................................................................................. 31
4.1 Safety notes for the electrical installation ....................................................................................31
4.2 Power distribution systems ..........................................................................................................32
4.3 Operation with ungrounded (IT) supplies.....................................................................................33
4.4 Operation with Residual Current Devices (RCD).........................................................................33
4.5 Motor cable length and cross section ..........................................................................................34
4.6 Access to power and motor terminals..........................................................................................36
4.7 Power and motor connections .....................................................................................................37
4.8 ESD guidelines ............................................................................................................................39
5 Service and maintenance ........................................................................................................................ 41
5.1 Maintenance.................................................................................................................................41
5.2 Replacing the cooling fan.............................................................................................................42
6 Technical specifications........................................................................................................................... 45
7 Accessories ............................................................................................................................................. 51
7.1 Reactor and filter..........................................................................................................................51
7.1.1 Line filter.......................................................................................................................................54
7.1.2 Output reactor ..............................................................................................................................57
7.1.3 Sine-wave filter.............................................................................................................................62
7.2 Brake Relay..................................................................................................................................67
7.3 Screen termination kit ..................................................................................................................70
A Appendix.................................................................................................................................................. 71
A.1 Electromagnetic Compatibility......................................................................................................71
A.2 Definition of the EMC Environment and Categories ....................................................................72
A.3 Standards.....................................................................................................................................74
A.4 Abbreviations ...............................................................................................................................75
Index........................................................................................................................................................ 77
Siemens Parts

Table of contents
PM250 Power Module
6 Hardware Installation Manual, 09/2012, A5E01003502B AD

PM250 Power Module
Hardware Installation Manual, 09/2012, A5E01003502B AD 7
Introduction 1
The SINAMICS G120 range
The SINAMICS G120 inverter has been designed for the accurate and efficient control of the
speed and torque for three-phase motors. The SINAMICS G120 system comprises two basic
modules, the Control Unit (CU) and the Power Module (PM).
The Control Units are divided into the following:
● CU without fail-safe functions
– CU230P-2 HVAC for pump and fan applications with Modbus RTU interface
– CU230P-2 CAN for pump and fan applications with CANopen interface
– CU230P-2 DP for pump and fan applications with PROFIBUS DP interface
– CU240E economic version of the CU240 Control Units (e.g. less terminals, no
encoder interface)
– CU240S standard version of the CU240 Control Units
– CU240S DP like CU240S plus PROFIBUS DP interface (PROFIdrive Profile V4.1)
– CU240S PN like CU240S plus PROFINET interface (PROFIdrive Profile V4.1)
● CU with fail-safe functions
– CU240S DP-F like CU240S DP plus integrated fail-safe functions
– CU240S PN-F like CU240S PN plus integrated fail-safe functions
The Power Modules differ concerning the supply voltage and the way of realizing the motor
braking function:
● PM240 Power Module with resistor braking and dc braking functions, supply voltage
3 AC 400 V
● PM250 Power Module with regenerative braking function, supply voltage 3 AC 400 V
● PM260 Power Module with regenerative braking function, supply voltage 3 AC 690 V
Control Units and Power Modules are allowed to be combined in any possible configuration.
Exceptions:
The CU230P-2 with firmware V4.2 can not be combined with PM240 FSGX or PM260.
These combinations will be allowed with firmware V4.3.
See the respective manual for specific functions and features.
Siemens Parts

Introduction
1.1 Power Modules PM250
PM250 Power Module
8 Hardware Installation Manual, 09/2012, A5E01003502B AD
1.1 Power Modules PM250
Available Power Modules
There are the following types of Power Modules with regenerative braking capacity. The
given power rating values are defined for "high overload" operation.
● Unfiltered Power Modules
380V … 480 V, IP20, frame sizes D … F, 15 kW … 75 kW
● Power Modules with integrated Class A filter
380V … 480 V, IP20, frame sizes C … F, 5.5 kW … 75 kW

Introduction
1.2 Block diagram
PM250 Power Module
Hardware Installation Manual, 09/2012, A5E01003502B AD 9
1.2 Block diagram
Block diagram
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Siemens Parts

Introduction
1.3 Documents for the Inverter
PM250 Power Module
10 Hardware Installation Manual, 09/2012, A5E01003502B AD
1.3 Documents for the Inverter
Available technical documentation
Comprehensive information and support tools are available from the Service and Support
internet site
● http://support.automation.siemens.com
You find there the following types of documentation:
● Getting Started
● Operating Instructions
● Hardware Installation Manual
● Function Manual
● Parameter Manual
● Product Information
Further internet addresses
You can download the respective documents for your inverter under the following links:
● SINAMICS G110
http://www.siemens.com/sinamics-g110
● SINAMICS G120
http://www.siemens.com/sinamics-g120
● SINAMICS G120D
http://www.siemens.com/sinamics-g120d
● SIMATIC ET 200S FC
http://www.siemens.com/et200s-fc
● SIMATIC ET 200pro FC
http://www.siemens.com/et200pro-fc
Application examples
You find various application examples to the inverters under the following link:
● http://support.automation.siemens.com/WW/view/en/20208582/136000

PM250 Power Module
Hardware Installation Manual, 09/2012 11
Safety instructions 2
Safety Instructions
The following Warnings, Cautions and Notes are provided for your safety and as a means of
preventing damage to the product or components in the connected machines. This section
lists Warnings, Cautions and Notes, which apply generally when handling the inverter,
classified as General, Transport and Storage, Commissioning, Operation, Repair and
Dismantling and Disposal.
Specific Warnings, Cautions and Notes that apply to particular activities are listed at the
beginning of the relevant sections in this manual and are repeated or supplemented at
critical points throughout these sections.
Please read the information carefully, since it is provided for your personal safety and will
also help prolong the service life of your inverter and the equipment to which it is connected.
Common Instructions
It has to be ensured by the machine manufacturer, that the line-side overcurrent protection
equipment interrupts within 5 s (immovable equipment and modules in immovable
equipment) in the case of minimum fault current (current on complete insulation failure to
accessible conductive parts that are not live during operation and maximum current loop
resistance).
It has to be ensured by the machine manufacturer, that the voltage drop between the
beginning of the load system and the power drive system during operation with rated values
does not exceed 4 %.
Siemens Parts

Safety instructions
PM250 Power Module
12 Hardware Installation Manual, 09/2012, A5E01003502B AD
General
WARNING
This equipment contains dangerous voltages and controls potentially dangerous rotating
mechanical parts. Non-compliance with the warnings or failure to follow the instructions
contained in this manual can result in loss of life, severe personal injury or serious damage
to property.
Protection in case of direct contact by means of SELV / PELV is only permissible in areas
with equipotential bonding and in dry indoor rooms. If these conditions are not fulfilled,
other protective measures against electric shock must be applied e.g. protective insulation.
Only suitably qualified personnel should work on this equipment, and only after becoming
familiar with all safety notices, installation, operation and maintenance procedures
contained in this manual. The successful and safe operation of this equipment is dependent
upon its proper handling, installation, operation and maintenance.
As the earth leakage for this product can be greater than 3.5 mA a.c., a fixed earth
connection is required and the minimum size of the protective earth conductor shall comply
with the local safety regulations for high leakage current equipment.
The power supply, DC and motor terminals, the brake and thermistor cables can carry
dangerous voltages even if the inverter is inoperative. Wait at least five minutes to allow the
unit to discharge after switching off the line supply before carrying out any installation work.
It is strictly prohibited for any mains disconnection to be performed on the motor-side of the
system; any disconnection of the mains must be performed on the mains-side of the
Inverter.
When connecting the line supply to the Inverter, make sure that the terminal case of the
motor is closed.
This equipment is capable of providing internal motor overload protection according to
UL508C. Refer to P0610 and P0335, i²t is ON by default.
When changing from the ON to OFF-state of an operation if an LED or other similar display
is not lit or active; this does not indicate that the unit is switched-off or powered-down.
The inverter must always be grounded.
Isolate the line supply before making or changing connections to the unit.
Ensure that the inverter is configured for the correct supply voltage. The inverter must not
be connected to a higher voltage supply.
Static discharges on surfaces or interfaces that are not generally accessible (e.g. terminal
or connector pins) can cause malfunctions or defects. Therefore, when working with
inverters or inverter components, ESD protective measures should be observed.
Take particular notice of the general and regional installation and safety regulations
regarding work on dangerous voltage installations (e.g. EN 50178) as well as the relevant
regulations regarding the correct use of tools and personal protective equipment (PPE).

Safety instructions
PM250 Power Module
Hardware Installation Manual, 09/2012, A5E01003502B AD 13
CAUTION
Children and the general public must be prevented from accessing or approaching the
equipment!
This equipment may only be used for the purpose specified by the manufacturer.
Unauthorized modifications and the use of spare parts and accessories that are not sold or
recommended by the manufacturer of the equipment can cause fires, electric shocks and
injuries.
Note
Keep this manual within easy reach of the equipment and make it available to all users.
Whenever measuring or testing has to be performed on live equipment, the regulations of
Safety Code BGV A2 must be observed, in particular § 8 "Permissible Deviations when
Working on Live Parts". Suitable electronic tools should be used.
Before installing and commissioning, please read these safety instructions and warnings
carefully and all the warning labels attached to the equipment. Make sure that the warning
labels are kept in a legible condition and replace missing or damaged labels.
Transport and storage
WARNING
Correct transport, storage as well as careful operation and maintenance are essential for
the proper and safe operation of the equipment.
CAUTION
Protect the equipment against physical shocks and vibration during transport and storage. It
is important that the equipment is protected from water (rainfall) and excessive
temperatures.
Commissioning
WARNING
Working on the equipment by unqualified personnel or failure to comply with warnings can
result in severe personal injury or serious damage to material. Only suitably qualified
personnel trained in the setup, installation, commissioning and operation of the product
should carry out work on the equipment.
Siemens Parts

Safety instructions
PM250 Power Module
14 Hardware Installation Manual, 09/2012, A5E01003502B AD
CAUTION
Cable connection
The control cables must be laid separately from the power cables. Carry out the
connections as shown in the installation section in this manual, to prevent inductive and
capacitive interference from affecting the correct function of the system.
Mechanical Installation
WARNING
To ensure the safe operation of the equipment, it must be installed and commissioned by
qualified personnel in full compliance with the warnings laid down in this manual.
Take particular note of the general and regional installation and safety regulations
regarding work on dangerous voltage installation (e.g. EN 61800-5-1) as well as the
relevant regulations regarding the correct use of tools and personal protective equipment
(PPE).
WARNING
Power and motor connections
The inverter must be grounded from the supply side and the motor side. If it is not grounded
correctly, extremely dangerous conditions may arise which could prove potentially fatal.
Isolate the mains electrical supply before making or changing connections to the unit.
Ensure that the appropriate circuit-breakers/fuses with the specified current rating are
connected between the power supply and the inverter.
The terminals of the Inverter can carry dangerous voltages even if the inverter is
inoperative. Wait at least 5 minutes to allow the unit to discharge after switching off the line
supply before carrying out any installation work.
When connecting the line supply to the inverter, make sure that the terminal case of the
motor is closed.
When changing from the ON to OFF-state of an operation if an LED or other similar display
is not lit or active; this does not indicate that the unit is switched-off or powered-down.
Ensure that the inverter is configured for the correct supply voltage – it must not be
connected to a higher voltage supply.

Safety instructions
PM250 Power Module
Hardware Installation Manual, 09/2012, A5E01003502B AD 15
Operation
WARNING
The inverter operates at high voltages. When operating electrical devices, it is impossible to
avoid applying hazardous voltages to certain parts of the equipment.
The power supply and motor terminals - and if available the DC terminals - can carry
dangerous voltages even if the inverter is inoperative. Wait five minutes to allow the unit to
discharge after switching off the line supply before carrying out any installation work.
Emergency Stop facilities according to EN 60204, IEC 204 (VDE 0113) must remain
operative in all operating modes of the control equipment. Any disengagement of the
Emergency Stop facility must not lead to an uncontrolled or an undefined restart of the
equipment.
Wherever faults occurring in the control equipment can lead to substantial material damage
or even grievous bodily injury (that is, potentially dangerous faults), additional external
precautions must be taken or facilities provided to ensure or enforce safe operation, even
when a fault occurs (e.g. independent limit switches, mechanical interlocks, etc.).
Certain parameter settings may cause the inverter to restart automatically after an input
power failure, for example, the automatic restart function.
Motor parameters must be accurately configured for motor overload protection to operate
correctly.
This equipment is suitable for use in a power system up to 10,000 symmetrical amperes
(rms), for the maximum rated voltage + 10 % when protected by an appropriate standard
fuse (refer to the catalogue for the type of fuse).
The Power Modules are components with a high leakage current!
Use of mobile radio device (e.g. telephones, walky-talkies) with a transmission power > 1 W
in the immediate vicinity of the devices (< 1.5 m) can interfere with the functioning of the
equipment!
CAUTION
The line filter conducts a high leakage current via the PE conductor. Due to the high
leakage current a permanent PE connection for the line filter is required.
Furthermore, the following measures must be taken in accordance with EN 61800-5-1:
Either protective ground conductor cross-sections ≥ 10 mm2 (8 AWG) Cu or installation of a
second protective ground conductor with both having the same cross-section as the line
input cable.
Siemens Parts

Safety instructions
2.1 Residual risks
PM250 Power Module
16 Hardware Installation Manual, 09/2012, A5E01003502B AD
Repair
WARNING
Repairs on equipment may only be carried out by Siemens Service, by repair centers
authorized by Siemens or by authorized personnel who are thoroughly acquainted with all
the warnings and operating procedures contained in this manual.
Any defective parts or components must be replaced using parts contained in the relevant
spare parts list.
Disconnect the power supply before opening the equipment for access.
Dismantling and disposal
NOTICE
The packaging of the inverter is re-usable. Retain the packaging for future use.
Easy-to-release screw and snap connectors allow you to break the unit down into its
component parts. You can recycle these component parts, dispose of them in accordance
with local requirements or return them to the manufacturer.
2.1 Residual risks
Residual risks of power drive systems
The control and drive components of a power drive system (PDS) are approved for industrial
and commercial use in industrial line supplies. Their use in public line supplies requires a
different configuration and/or additional measures.
These components may only be operated in closed housings or in higher-level control
cabinets with protective covers that are closed, and when all of the protective devices are
used.
These components may only be handled by qualified and trained technical personnel who
are knowledgeable and observe all of the safety information and instructions on the
components and in the associated technical user documentation.
When carrying out a risk assessment of a machine in accordance with the EU Machinery
Directive, the machine manufacturer must consider the following residual risks associated
with the control and drive components of a power drive system (PDS).
1. Unintentional movements of driven machine components during commissioning,
operation, maintenance, and repairs caused by, for example:

Safety instructions
2.1 Residual risks
PM250 Power Module
Hardware Installation Manual, 09/2012, A5E01003502B AD 17
– Hardware defects and/or software errors in the sensors, controllers, actuators, and
connection technology
– Response times of the controller and drive
– Operating and/or ambient conditions outside of the specification
– Condensation / conductive contamination
– Parameterization, programming, cabling, and installation errors
– Use of radio devices / cellular phones in the immediate vicinity of the controller
– External influences / damage
2. In the event of a fault, exceptionally high temperatures, including an open fire, as well as
emissions of light, noise, particles, gases, etc. can occur inside and outside the inverter,
e.g.:
– Component malfunctions
– Software errors
– Operating and/or ambient conditions outside of the specification
– External influences / damage
Inverters of the Open Type / IP20 degree of protection must be installed in a metal
enclosure (or protected by another equivalent measure) in such a way that the contact with
fire inside and outside the inverter is prevented.
3. Hazardous shock voltages caused by, for example:
– Component malfunctions
– Influence of electrostatic charging
– Induction of voltages in moving motors
– Operating and/or ambient conditions outside of the specification
– Condensation / conductive contamination
– External influences / damage
4. Electrical, magnetic and electromagnetic fields generated in operation that can pose a
risk to people with a pacemaker, implants or metal replacement joints, etc. if they are too
close.
5. Release of environmental pollutants or emissions as a result of improper operation of the
system and/or failure to dispose of components safely and correctly.
Note
The components must be protected against conductive contamination (e.g. by installing them
in a cabinet with degree of protection IP54B to EN 60529).
Assuming that conductive contamination at the installation site can definitely be excluded, a
lower degree of cabinet protection may be permitted.
For more information about residual risks of the components in a power drive system, see
the relevant chapters in the technical user documentation.
Siemens Parts

Safety instructions
2.1 Residual risks
PM250 Power Module
18 Hardware Installation Manual, 09/2012, A5E01003502B AD

PM250 Power Module
Hardware Installation Manual, 09/2012, A5E01003502B AD 19
Installing/Mounting 3
WARNING
To ensure the safe operation of the equipment, it must be installed and commissioned by
qualified personnel in full compliance with the warnings laid down in this manual.
Take particular note of the general and regional installation and safety regulations
regarding work on dangerous voltage installation (e.g. EN 61800-5-1) as well as the
relevant regulations regarding the correct use of tools and personal protective equipment
(PPE).
3.1 Installation conditions
General rules for the environmental protection of the Power Modules
To ensure that the power module is installed in the correct environmental conditions, please
ensure that you adhere to the following guidelines:
● The Power Module is designed for IP20 protection. It is protected from the ingress of solid
foreign objects ≥ 12.5 mm (≥ 0.49 inches).
● The Power Module is not protected against the ingress of water.
● The Power Module is designed to be installed in an electrical cabinet.
● Keep the Power Module free from dust and dirt.
● Keep the Power Module away from water, solvents and chemicals.
Take care to site the inverter away from potential water hazards, for example, do not
install the inverter beneath pipes that are subject to condensation. Avoid installing the
inverter where excessive humidity and condensation may occur.
● Keep the Power Module within the maximum and minimum operating temperatures.
● Ensure that the correct level of ventilation and air flow is provided.
● Ensure that earthing and grounding practices for each Power Module and the cabinet
follows the guidelines given in this document.
CAUTION
The Power Module MUST NOT be mounted horizontally.
Siemens Parts

Installing/Mounting
3.2 Air cooling requirements
PM250 Power Module
20 Hardware Installation Manual, 09/2012, A5E01003502B AD
3.2 Air cooling requirements
Installation and cooling
Make sure that there is an adequate airflow through the cubicle as follows:
1. Add the air flow values required for every Power Module (see following table) within the
cubicle
2. Calculate the airflow required by components as reactor, filter, Control Unit and other
electronic devices using the formula
Air flow (l/s) = (Power loss (Watt) / ΔT) x 0.86
(ΔT = Allowable temperature rise within the cubicle in °C).
For the power losses of components see the following table
3. Add the airflow values of all components within the cubicle to get the complete air flow
required
4. No equipment should be installed that could have a negative effect on the flow of cooling
air
5. Make sure that the cooling vents in the Power Module are positioned correctly to allow
the free movement of air
6. Avoid cooling air short circuit using air barriers, if necessary
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7. Provide an adequate cubicle with sufficient air vent and suitable air strainer