Siemens PM330 Assembly instructions

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SINAMICS
SINAMICS G120P
Power Module PM330
Hardware Installation Manual
Firmware V4.7 SP10
12/2018
A5E32844552B AF
Basic safety instructions
1
Introduction
2
Installing/Mounting
3
Connecting up, switching on
4
Service and maintenance
5
Technical specifications
6
Fundamental safety
technology principles
7
Safety functions of PM330
8
Appendix
A

Siemens AG
Division Process Industries and Drives
Postfach 48 48
90026 NÜRNBERG
GERMANY
A5E32844552B AF
Ⓟ
01/2019 Subject to change
Copyright © Siemens AG 2013 - 2018.
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.

Power Module PM330
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Table of contents
1 Basic safety instructions.......................................................................................................................... 7
1.1 General safety instructions .......................................................................................................7
1.2 Handling electrostatic sensitive devices (ESD) ......................................................................11
1.3 Industrial security ....................................................................................................................12
1.4 Residual risks of power drive systems....................................................................................14
2 Introduction........................................................................................................................................... 15
3 Installing/Mounting ................................................................................................................................ 19
3.1 Installation conditions..............................................................................................................19
3.2 Power losses and air cooling requirements ............................................................................21
3.3 Mounting the Power Modules .................................................................................................23
3.3.1 Chassis units...........................................................................................................................26
3.4 Control Unit installation ...........................................................................................................29
4 Connecting up, switching on.................................................................................................................. 31
4.1 Cable lugs ...............................................................................................................................32
4.2 Line, motor and DC link connection........................................................................................33
4.2.1 Protective conductor ...............................................................................................................33
4.2.2 Line connection.......................................................................................................................34
4.2.3 Length of motor cables ...........................................................................................................34
4.2.4 Motor connection ....................................................................................................................35
4.2.5 Access to power and motor terminals.....................................................................................36
4.2.6 DC link connection ..................................................................................................................40
4.3 Operation on a non-grounded line supply (IT system) ...........................................................41
4.4 Installation set for line-side cable connection, left ..................................................................43
4.5 Terminal strip X9.....................................................................................................................49
4.6 Terminal block X41 / switch S41.............................................................................................51
4.6.1 Terminal strip X41...................................................................................................................52
4.6.2 Switch S41 ..............................................................................................................................53
4.6.3 Schematic diagram of the safety relay at X41 ........................................................................54
4.7 EMC compliant connection .....................................................................................................55
4.7.1 Avoiding electromagnetic interference....................................................................................55
4.7.2 EMC-compliant cabinet design ...............................................................................................55
4.7.3 Cabinet design ........................................................................................................................56
4.7.4 Cabling....................................................................................................................................57
4.7.5 Equipotential bonding .............................................................................................................59
4.8 Switching on............................................................................................................................62

Table of contents
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5 Service and maintenance...................................................................................................................... 63
5.1 Maintenance........................................................................................................................... 63
5.2 Forming .................................................................................................................................. 65
5.3 Replacing fans ....................................................................................................................... 67
5.3.1 Service life of the cooling fan ................................................................................................. 67
5.3.2 Fan replacement GX.............................................................................................................. 67
5.3.3 Fan replacement for HX, JX................................................................................................... 69
5.4 Replacing additional components.......................................................................................... 71
5.4.1 Opening the device ................................................................................................................ 71
5.4.2 Replacing the PSB module .................................................................................................... 73
5.4.3 Replacing the FPI module...................................................................................................... 74
5.4.4 Replacing the electronics fan................................................................................................. 76
5.4.5 Replacing the current transformer ......................................................................................... 77
6 Technical specifications ........................................................................................................................ 81
6.1 General technical data ........................................................................................................... 82
6.2 Specific technical data ........................................................................................................... 87
6.3 Derating data.......................................................................................................................... 99
6.3.1 Derating factor of the output current as a function of the ambient temperature in
operation ................................................................................................................................ 99
6.3.2 Derating as a function of the installation altitude ................................................................. 100
6.3.3 Derating factor of the output current as a function of the line voltage ................................. 103
6.3.4 Derating of the output current as a function of the pulse frequency .................................... 103
6.4 Data regarding the power loss in partial load operation ...................................................... 104
7 Fundamental safety technology principles ............................................................................................105
7.1 Standard stop functions ....................................................................................................... 105
7.1.1 Emergency Off and Emergency Stop .................................................................................. 105
7.2 Standard safety functions according to EN 61800-5-2 ........................................................ 106
7.2.1 Safe Torque Off (STO)......................................................................................................... 106
7.2.2 Safe Stop 1 (SS1-t, time controlled) .................................................................................... 107
8 Safety functions of PM330 ...................................................................................................................109
8.1 Technical fundamentals of PM330 Power Module .............................................................. 109
8.1.1 General fundamentals and data........................................................................................... 109
8.1.2 PM330 application with safety relay..................................................................................... 110
8.2 Safety functions that can be implemented........................................................................... 110
8.3 Validating/checking the safety function................................................................................ 113
8.4 Diagnostics test/online test .................................................................................................. 114
8.5 Relationship between the test stop interval and SIL or PL and Cat. ................................... 114
8.6 Safe brake control/brake control in general ......................................................................... 114
8.6.1 Brake control via external relays/controls ............................................................................ 114

Table of contents
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A Appendix............................................................................................................................................. 115
A.1 Further information on your converter ..................................................................................115
A.1.1 Manuals for your inverter ......................................................................................................115
A.1.2 Configuring support...............................................................................................................116
A.1.3 Product Support ....................................................................................................................116
A.1.4 Certificates ............................................................................................................................117
A.2 Electromagnetic compatibility ...............................................................................................117
A.2.1 Definition of the EMC Environment and Categories .............................................................117
A.2.2 Compliance with EMC Environment and Categories............................................................118
A.2.3 EMC limit values in South Korea ..........................................................................................120
A.3 Application examples for functional safety (STO / SS1-t).....................................................121
A.3.1 General requirements ...........................................................................................................121
A.3.2 Stop Category 0 (STO) .........................................................................................................122
A.3.2.1 SIRIUS 3SK1 with relay outputs, separate power supply for the 3SK1 and PM330............122
A.3.2.2 3SK1 power supply via X9 from the PM330 .........................................................................124
A.3.2.3 External power supply for 3SK1 and PM330........................................................................125
A.3.3 Stop Category 1 (SS1-t)........................................................................................................126
A.3.3.1 SIRIUS 3SK1121 with relay outputs .....................................................................................126
A.3.3.2 F-PLC....................................................................................................................................128
A.3.4 Troubleshooting examples....................................................................................................130
A.4 Acceptance test/configuration test........................................................................................134
A.4.1 Acceptance test STO............................................................................................................135
A.4.2 SS1-t acceptance test...........................................................................................................137
A.4.3 Documentation of the acceptance test .................................................................................139
A.5 Environmental compatibility ..................................................................................................141
A.6 Abbreviations ........................................................................................................................142
Index................................................................................................................................................... 145

Table of contents
Power Module PM330
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Power Module PM330
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Basic safety instructions
1
1.1
General safety instructions
DANGER
Electric shock and danger to life due to other energy sources
Touching live components can result in death or serious injury.
•Only work on electrical equipment if you are appropriately qualified.
•Always observe the country-specific safety rules for all work.
Generally, the following six steps apply when establishing safety:
1. Prepare for disconnection. Notify all those who will be affected by the procedure.
2. Isolate the drive system from the power supply and take measures to prevent it being
switched back on again.
3. Wait until the discharge time specified on the warning labels has elapsed.
4. Check that there is no voltage between any of the power connections, and between any
of the power connections and the protective conductor connection.
5. Check that every auxiliary circuit is de-energized.
6. Ensure that the motors cannot move.
7. Identify all other dangerous energy sources, e.g. compressed air, hydraulic systems, or
water. Switch the energy sources to a safe state.
8. Check that the correct drive system is completely locked.
After you have completed the work, restore the operational readiness by following the
above steps in the reverse order.
WARNING
Electric shock due to connection to an unsuitable power supply
When equipment is connected to an unsuitable power supply, exposed components may
carry a hazardous voltage that might result in serious injury or death.
•Only use power supplies that provide SELV (Safety Extra Low Voltage) or PELV
(Protective Extra Low Voltage) output voltages for all connections and terminals of the
electronics modules.

Basic safety instructions
1.1 General safety instructions
Power Module PM330
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WARNING
Electric shock due to damaged equipment
Improper handling of devices can cause damage.
For damaged devices, hazardous voltages can be present at the enclosure or at exposed
components; if touched, this can result in death or severe injury.
•Ensure compliance with the limit values specified in the technical data during transport,
storage and operation.
•Do not use any damaged devices.
WARNING
Electric shock due to cable shields that have not been connected
Hazardous touch voltages can occur through capacitive cross-coupling due to unconnected
cable shields.
•Connect cable shields and unused conductors of power cables (e.g. brake conductors)
at least on one side to the grounded housing potential.
WARNING
Electric shock if there is no ground connection
For missing or incorrectly implemented protective conductor connection for devices with
protection class I, high voltages can be present at open, exposed parts, which when
touched, can result in death or severe injury.
•Ground the device in compliance with the applicable regulations.
WARNING
Arcing when a plug connection is opened during operation
Opening a plug connection when a system is in operation can result in arcing that may
cause serious injury or death.
•Only open plug connections when the equipment is in a voltage-free state, unless it has
been explicitly stated that they can be opened in operation.
WARNING
Electric shock due to residual charges in power components
Because of the capacitors, a hazardous voltage is present for up to 5 minutes after the
power supply has been switched off. Contact with live parts can result in death or serious
injury.
•Wait for 5 minutes before you check that the unit really is in a no-voltage condition and
start work.

Basic safety instructions
1.1 General safety instructions
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NOTICE
Material damage due to loose power connections
Insufficient tightening torques or vibration can result in loose power connections. This can
result in damage due to fire, device defects, or malfunctions.
•Tighten all power connections to the prescribed torque.
•Check all power connections at regular intervals, particularly after equipment has been
transported.
WARNING
Spread of fire from built-in devices
In the event of fire outbreak, the enclosures of built-in devices cannot prevent the escape of
fire and smoke. This can result in serious personal injury or property damage.
•Install built-in units in a suitable metal cabinet in such a way that personnel are
protected against fire and smoke, or take other appropriate measures to protect
personnel.
•Ensure that smoke can only escape via controlled and monitored paths.
WARNING
Active implant malfunctions due to electromagnetic fields
Inverters generate electromagnetic fields (EMF) in operation. People with active implants in
the immediate vicinity of this equipment are at particular risk.
•As the operator of an EMF-emitting installation, assess the individual risks of persons
with active implants. The following clearances are usually adequate:
–No clearance to closed control cabinets and shielded MOTION-CONNECT supply
cables
–Forearm length (approx. 35 cm clearance) to distributed drive systems and open
control cabinets
WARNING
Unexpected movement of machines caused by radio devices or mobile phones
When radio devices or mobile phones with a transmission power > 1 W are used in the
immediate vicinity of components, they may cause the equipment to malfunction.
Malfunctions may impair the functional safety of machines and can therefore put people in
danger or lead to property damage.
•If you come closer than around 2 m to such components, switch off any radio devices or
mobile phones.
•Use the "SIEMENS Industry Online Support App" only on equipment that has already
been switched off.

Basic safety instructions
1.1 General safety instructions
Power Module PM330
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WARNING
Motor fire in the event of insulation overload
There is a greater load on the motor insulation through a ground fault in an IT system. If the
insulation fails, it is possible that death or severe injury can occur as a result of smoke and
fire.
•Use a monitoring device that signals an insulation fault.
•Correct the fault as quickly as possible so the motor insulation is not overloaded.
WARNING
Fire due to inadequate ventilation clearances
Inadequate ventilation clearances can cause overheating of components with subsequent
fire and smoke. This can cause severe injury or even death. This can also result in
increased downtime and reduced service lives for devices/systems.
•Ensure compliance with the specified minimum clearance as ventilation clearance for
the respective component.
WARNING
Unrecognized dangers due to missing or illegible warning labels
Dangers might not be recognized if warning labels are missing or illegible. Unrecognized
dangers may cause accidents resulting in serious injury or death.
•Check that the warning labels are complete based on the documentation.
•Attach any missing warning labels to the components, where necessary in the national
language.
•Replace illegible warning labels.
NOTICE
Device damage caused by incorrect voltage/insulation tests
Incorrect voltage/insulation tests can damage the device.
•Before carrying out a voltage/insulation check of the system/machine, disconnect the
devices as all inverters and motors have been subject to a high voltage test by the
manufacturer, and therefore it is not necessary to perform an additional test within the
system/machine.

Basic safety instructions
1.2 Handling electrostatic sensitive devices (ESD)
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WARNING
Unexpected movement of machines caused by inactive safety functions
Inactive or non-adapted safety functions can trigger unexpected machine movements that
may result in serious injury or death.
•Observe the information in the appropriate product documentation before
commissioning.
•Carry out a safety inspection for functions relevant to safety on the entire system,
including all safety-related components.
•Ensure that the safety functions used in your drives and automation tasks are adjusted
and activated through appropriate parameterizing.
•Perform a function test.
•Only put your plant into productive operation once you have absolutely guaranteed that
the functions relevant to safety are operating correctly.
1.2
Handling electrostatic sensitive devices (ESD)
Electrostatic sensitive devices (ESDs) are individual components, integrated circuits,
modules or devices that may be damaged by either electrostatic fields or electrostatic
discharge.
NOTICE
Damage caused by electric fields or electrostatic discharge
Electric fields or electrostatic discharge can result in malfunctions as a result of damaged
individual parts, integrated circuits, modules or devices.
•Only pack, store, transport and send electronic components, modules or devices in their
original packaging or in other suitable materials, e.g conductive foam rubber of
aluminum foil.
•Only touch components, modules and devices if you are first grounded by applying one
of the following measures:
–Wearing an ESD wrist strap
–Wearing ESD shoes or ESD grounding straps in ESD areas with conductive flooring
•Only place electronic components, modules or devices on conductive surfaces (table
with ESD surface, conductive ESD foam, ESD packaging, ESD transport container).

Basic safety instructions
1.3 Industrial security
Power Module PM330
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1.3
Industrial security
Note
Industrial security
Siemens provides products and solutions with industrial security functions that support the
secure operation of p
lants, systems, machines and networks.
In order to protect plants, systems, machines and networks against cyber threats, it is
necessary to implement
– and continuously maintain – a holistic, state-of-the-art industrial
security concept. Siemens products a
nd solutions only represent one component of such a
concept.
The customer is responsible for preventing unauthorized access to its plants, systems,
machines and networks. Systems, machines and components should only be connected to
the enterprise network o
r the internet if and to the extent necessary and with appropriate
security measures (e.g. use of firewalls and network segmentation) in place.
Additionally, Siemens’ guidance on appropriate security measures should be taken into
account. For more informa
tion about industrial security, please visit:
Industrial security (
http://www.siemens.com/industrialsecurity).
Siemens’ products and solutions undergo continuous development to make them more
secure. Siemens strongly recommends to apply product updates as soon as available and to
always use the latest product versions. Use of product versions that are no longer supported,
and failure to apply latest updates may increase customer’s exposure to cybe
r threats.
To stay informed about product updates, subscribe to the Siemens Industrial Security RSS
Feed at:
Industrial security (
http://www.siemens.com/industrialsecurity).
Addition information is provided on the Internet:
Industrial security Configuration Manual
(https://support.industry.siemens.com/cs/ww/en/view/108862708)

Basic safety instructions
1.4 Residual risks of power drive systems
Power Module PM330
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WARNING
Unsafe operating states resulting from software manipulation
Software manipulations (e.g. viruses, trojans, malware or worms) can cause unsafe
operating states in your system that may lead to death, serious injury, and property
damage.
•Keep the software up to date.
•Incorporate the automation and drive components into a state-of-the-art, integrated
industrial security concept for the installation or machine.
•Make sure that you include all installed products into the integrated industrial security
concept.
•Protect files stored on exchangeable storage media from malicious software by with
suitable protection measures, e.g. virus scanners.
•Protect the drive against unauthorized changes by activating the "Knowhow protection"
inverter function.

Basic safety instructions
1.4 Residual risks of power drive systems
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1.4
Residual risks of power drive systems
When assessing the machine- or system-related risk in accordance with the respective local
regulations (e.g. EC Machinery Directive), the machine manufacturer or system installer
must take into account the following residual risks emanating from the control and drive
components of a drive system:
1. Uncontrolled motion of the driven machine or system components during commissioning,
operation, maintenance and repair caused by, for example:
–Hardware and/or software errors in the sensors, control system, actuators and cables
and connections
–Response times of the controller and drive
–Operation and/or environmental conditions outside the specification
–Condensation/conductive pollution
–Parameterization, programming, cabling, and installation errors
–Use of wireless devices/mobile phones in the immediate vicinity of electronic
components
–External influence/damage
–X-ray, ionizing radiation and cosmic radiation
2. Unusually high temperatures - including open flames - as well as the emission of light,
noise, particles, gases, etc. can occur inside and outside the components under fault
conditions caused by, for example:
–Component malfunctions
–Software errors
–Operation and/or environmental conditions outside the specification
–External influence/damage
3. Hazardous shock voltages caused by, for example:
–Component malfunctions
–Influence of electrostatic charging
–Induction of voltages in moving motors
–Operation and/or environmental conditions outside the specification
–Condensation/conductive pollution
–External influence/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
6. Influence of network-connected communication systems, e.g. ripple-control transmitters
or data communication via the network
For more information about the residual risks of the drive system components, see the
relevant sections in the technical user documentation.

Power Module PM330
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Introduction
2
Power Module - PM330
The PM330 Power Module is a part of the modular family of SINAMICS G120 inverters.
PM330 Power Modules have been specifically optimized for driving pumps, fans, blowers
and compressors with square-law load characteristic for use in HVAC applications. The
Power Module is available with the "internal air cooling" cooling method.
The Power Modules are available for the following rated voltages and rated powers:
●3 AC 380 V … 480 V: 160 kW … 560 kW
●3 AC 500 V … 690 V: 315 kW … 630 kW
The Power Modules can be connected to the following line supply systems:
●TN system
●TT system
●IT system
690-V line supplies with grounded line conductor are not permitted.
As standard, a line reactor (uk≥ 2 %) must be provided at the line input (see the following
diagram).

Introduction
Power Module PM330
16 Hardware Installation Manual, 12/2018, A5E32844552B AF
Figure 2-1 PM330 block diagram

Introduction
Power Module PM330
Hardware Installation Manual, 12/2018, A5E32844552B AF 17
Note
Principle of the precharging circuit
SINAMICS PM330 Power Modules include a half
-controlled thyristor bridge as rectifier
circuit. As a result of the precharging principle with phase control, precharging is only started
when all of the enable signals are available and by setting the ON/OFF command
(p0840
= 1).
The DC link is then fully charged af
ter approximately 4 s.
The Power Modules can be used with the following Control Units, including all
communication versions with firmware version from 4.6 HF7 and higher.
•
CU230P-2 PN
6SL3243
-0BB30-1FAx
•
CU230P-2 DP
6SL3243
-0BB30-1PAx
•
CU230P-2 HVAC
6SL
3243-0BB30-1HAx
Operation with Control Units other than those listed above is not permitted.

Introduction
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