Siemens SINAMICS S120 User manual

AC Drive
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SINAMICS
S120
AC Drive
Manual
(GH6), 04/2014
6SL3097
-4AL00-0BP4
Foreword
Fundamental safety
instructions
1
System overview
2
Mains connection and line-
side power components
3
Power Modules
4
DC link components
5
Motor-side power
components
6
Control Units, Control Unit
Adapters and operating
components
7
Supplementary system
components and encoder
system integration
8
Accessories
9
Cabinet design and EMC for
components, Blocksize
format
10
Service and maintenance
11
Appendix
A

Siemens AG
Industry Sector
Postfach 48 48
90026 NÜRNBERG
GERMANY
Order number: 6SL3097-4AL00-0BP4
Ⓟ
04/2014 Subject to change
Copyright © Siemens AG 2006 - 2014.
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.

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Manual, (GH6), 04/2014, 6SL3097-4AL00-0BP4 5
Foreword
SINAMICS documentation
The SINAMICS documentation is organized in the following categories:
●General documentation/catalogs
●User documentation
●Manufacturer/service documentation
More information
Using the following link, you can find information on the topics:
●Ordering documentation/overview of documentation
●Additional links to download documents
●Using documentation online (find and search in manuals/information)
http://www.siemens.com/motioncontrol/docu
Please send any questions about the technical documentation (e.g. suggestions for
improvement, corrections) to the following e-mail address:
[e-mail]
My Documentation Manager
Using the following link, you can find information on how to create your own individual
documentation based on Siemens content, and adapt it for your own machine
documentation:
http://www.siemens.com/mdm
Training
At the following link, you will find information on SITRAIN - training from Siemens for
products, systems, and drive and automation engineering solutions:
http://www.siemens.com/sitrain
FAQs
You can find Frequently Asked Questions in the Service&Support pages under
Product
Support
:
http://support.automation.siemens.com

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SINAMICS
You can find information on SINAMICS under:
http://www.siemens.com/sinamics
Usage phases and the available tools/documents
Table 1 Usage phases and the available documents/tools
Usage phase
Document/tool
Orientation
SINAMICS S sales documentation
Planning/engineering •SIZER configuration tool
•Configuration manuals, motors
Decision making/ordering SINAMICS S120 catalogs
•SIMOTION, SINAMICS S120 and Motors for Production
Machines (Catalog PM 21)
•SINAMICS and motors for single-axis drives (catalog D 31)
•SINUMERIK & SINAMICS
Equipment for Machine Tools (Catalog NC 61)
•SINUMERIK 840D sl Type 1B
Equipment for Machine Tools (Catalog NC 62)
Configuring/installation •SINAMICS S120 Equipment Manual for Control Units and
Additional System Components
•SINAMICS S120 Equipment Manual for Booksize Power
Units
•SINAMICS S120 Equipment Manual for Chassis Power
Units
•SINAMICS S120 Equipment Manual for AC Drives
•SINAMICS S120M Equipment Manual Distributed Drive
Technology
•SINAMICS HLA System Manual Hydraulic Drive
Commissioning •STARTER commissioning tool
•SINAMICS S120 Getting Started
•SINAMICS S120 Commissioning Manual
•SINAMICS S120 CANopen Commissioning Manual
•SINAMICS S120 Function Manual
•SINAMICS S120 Safety Integrated Function Manual
•SINAMICS S120/S150 List Manual
•SINAMICS HLA System Manual Hydraulic Drive
Using/operating •SINAMICS S120 Commissioning Manual
•SINAMICS S120/S150 List Manual
•SINAMICS HLA System Manual Hydraulic Drive

Foreword
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Manual, (GH6), 04/2014, 6SL3097-4AL00-0BP4 7
Usage phase
Document/tool
Maintenance/Service •SINAMICS S120 Commissioning Manual
•SINAMICS S120/S150 List Manual
List of references •SINAMICS S120/S150 List Manual
Target group
This documentation is intended for machine manufacturers, commissioning engineers, and
service personnel who use the SINAMICS drive system.
Benefits
This Manual provides all the information, procedures and operational instructions required
for commissioning and servicing SINAMICS S120.
Standard scope
The scope of the functionality described in this document can differ from the scope of the
functionality of the drive system that is actually supplied.
●Other functions that are not explained in this documentation may be able to be executed
in the drive system. However, no claim can be made regarding the availability of these
functions when the equipment is first supplied or in the event of servicing.
●The documentation can also contain descriptions of functions that are not available in a
particular product version of the drive system. The functionalities of the supplied drive
system should only be taken from the ordering documentation.
●Extensions or changes made by the machine manufacturer must be documented by the
machine manufacturer.
For reasons of clarity, this documentation does not contain all of the detailed information on
all of the product types. and cannot take into consideration every conceivable type of
installation, operation and service/maintenance.
Technical Support
Country-specific telephone numbers for technical support are provided in the Internet under
Contact
:
http://www.siemens.com/automation/service&support
EC Declarations of Conformity
The EC Declaration of Conformity for the EMC Directive can be found on the Internet at:
http://support.automation.siemens.com/WW/view/de/21901735/134200

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The EC Declaration of Conformity for the Low Voltage Directive can be found on the Internet
at:
http://support.automation.siemens.com
There – as a search term – enter the number
22383669
.
Note
When operated in dry areas, SINAMICS S units conform to the Low
-Voltage Directive
2006/95/EC.
Note
SINAMICS S units comply with the EMC Directive 2004/108/EC in the configuration specified
in the associated EC Declaration of Conformity for EMC and when the EMC installation
guideline provided in the Configuration Manual with Order No. 6FC5297
-0AD30-0xPx is
implemented.
Note
The E
quipment Manual describes a desired state which, if maintained, ensures the required
level of operational reliability and compliance with EMC limit values.
Should there be any deviation from the requirements in the manual, appropriate actions (e.g.
measure
ments) must be taken to check/prove that the required level of operational reliability
and compliance with EMC limit values are ensured.
EMC limit values in South Korea
The EMC limit values to be complied with for South Korea correspond to the limit values of
the EMC product standard for variable-speed electric drives EN 61800-3, Category C2 or
limit value class A, Group 1 according to EN55011. By applying suitable supplementary
measures, the limit values according to Category C2 or according to limit value class A,
Group 1 are maintained. Further, additional measures may be required, for instance, using
an additional radio interference suppression filter (EMC filter). The measures for EMC-
compliant design of the system are described in detail in this manual and in the
Configuration Manual "EMC installation guideline."
The measures for EMC-compliant design of the system are described in detail in this manual
respectively in the Installation Guideline EMC.
Please note that the final statement on compliance with the standard is always provided on
the label attached to each unit.
Spare parts
Spare parts are available on the Internet at:
http://support.automation.siemens.com/WW/view/de/16612315

Foreword
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Manual, (GH6), 04/2014, 6SL3097-4AL00-0BP4 9
Explanation of symbols
Table 2 Symbols
Symbol
Meaning
Protective earth (PE)
Ground (e.g. M 24 V)
Functional ground
Equipotential bonding

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Table of contents
Foreword ................................................................................................................................................ 5
1 Fundamental safety instructions............................................................................................................ 21
1.1 General safety instructions ..........................................................................................................21
1.2 Safety instructions for electromagnetic fields (EMF) ...................................................................24
1.3 Handling electrostatic sensitive devices (ESD) ...........................................................................25
1.4 Industrial security .........................................................................................................................25
1.5 Residual risks of power drive systems.........................................................................................26
2 System overview................................................................................................................................... 29
2.1 Field of application .......................................................................................................................29
2.2 Platform Concept and Totally Integrated Automation..................................................................31
2.3 Overview, SINAMICS S120 AC Drive..........................................................................................32
2.4 SINAMICS S120 components......................................................................................................33
2.5 System data .................................................................................................................................35
2.6 Derating as a function of the ambient temperature, pulse frequency, and installation
altitude..........................................................................................................................................37
3 Mains connection and line-side power components ............................................................................... 39
3.1 Introduction ..................................................................................................................................39
3.2 Information on the disconnector unit............................................................................................40
3.3 Overcurrent protection by means of line fuses and circuit breakers............................................41
3.4 Using residual-current devices.....................................................................................................41
3.5 Overvoltage protection.................................................................................................................42
3.6 Line contactors.............................................................................................................................43
3.7 Line filter.......................................................................................................................................44
3.7.1 Description ...................................................................................................................................44
3.7.2 Classification of EMC behavior....................................................................................................44
3.7.3 Electromagnetic compatibility (EMC) of the system ....................................................................45
3.7.4 Safety instructions for line filters ..................................................................................................47
3.7.5 Dimension drawings.....................................................................................................................48
3.7.6 Mounting ......................................................................................................................................53
3.7.7 Technical data..............................................................................................................................54
3.7.7.1 Technical data, Blocksize line filter ..............................................................................................54
3.7.7.2 Technical data, Chassis line filter ................................................................................................55
3.8 Line reactors ................................................................................................................................56
3.8.1 Description ...................................................................................................................................56
3.8.2 Safety instructions for line reactors..............................................................................................56

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3.8.3 Dimension drawings.................................................................................................................... 58
3.8.4 Mounting...................................................................................................................................... 64
3.8.5 Electrical Connection .................................................................................................................. 71
3.8.6 Technical data............................................................................................................................. 72
3.8.6.1 Blocksize line reactors ................................................................................................................ 72
3.8.6.2 Chassis line reactors................................................................................................................... 75
3.9 Line connection variants ............................................................................................................. 76
3.9.1 Operation on different line system configurations....................................................................... 76
3.9.2 Methods of line connection ......................................................................................................... 79
3.9.3 Operation of the line connection components on the supply line ............................................... 81
3.9.4 Operation of the line connection components via an autotransformer ....................................... 82
3.9.5 Operation of the line connection components via an isolating transformer ................................ 83
4 Power Modules ..................................................................................................................................... 85
4.1 Safety instructions for Power Modules........................................................................................ 85
4.2 Blocksize Power Modules (PM240-2) ......................................................................................... 88
4.2.1 Description .................................................................................................................................. 88
4.2.2 Safety information for 240-2 Power Modules.............................................................................. 90
4.2.3 Interface description.................................................................................................................... 91
4.2.3.1 Overview ..................................................................................................................................... 91
4.2.3.2 Connection example ................................................................................................................... 93
4.2.3.3 Line supply connection................................................................................................................ 94
4.2.3.4 Braking resistor and DC link connection ..................................................................................... 94
4.2.3.5 Motor connection......................................................................................................................... 94
4.2.3.6 Safe brake relay connection........................................................................................................ 95
4.2.4 Dimension drawings.................................................................................................................... 95
4.2.5 Mounting.................................................................................................................................... 103
4.2.5.1 Mounting dimensions and tightening torques ........................................................................... 104
4.2.5.2 Mounting the shielding plate ..................................................................................................... 105
4.2.6 Technical data........................................................................................................................... 106
4.2.6.1 200 V Power Modules ............................................................................................................... 106
4.2.6.2 400 V Power Modules ............................................................................................................... 111
4.2.6.3 Characteristics .......................................................................................................................... 117
4.3 Power Modules Blocksize (PM340) .......................................................................................... 121
4.3.1 Description ................................................................................................................................ 121
4.3.2 Safety instructions for Power Modules blocksize format .......................................................... 123
4.3.3 Interface description.................................................................................................................. 124
4.3.3.1 Overview ................................................................................................................................... 124
4.3.3.2 Connection example ................................................................................................................. 130
4.3.3.3 Line supply connection.............................................................................................................. 132
4.3.3.4 Braking resistor and DC link connection ................................................................................... 132
4.3.3.5 Motor connection....................................................................................................................... 133
4.3.3.6 Safe brake relay connection...................................................................................................... 133
4.3.4 Dimension drawings.................................................................................................................. 134
4.3.5 Mounting.................................................................................................................................... 142
4.3.5.1 Mounting dimensions and tightening torques ........................................................................... 142
4.3.5.2 Access to the power supply terminals and motor terminals...................................................... 144
4.3.6 Technical data........................................................................................................................... 145
4.3.6.1 Power Modules Blocksize, 1-ph. AC......................................................................................... 145
4.3.6.2 Power Modules Blocksize, 3-ph. AC......................................................................................... 147
4.3.6.3 Characteristics .......................................................................................................................... 154

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4.4 Power Modules Chassis ............................................................................................................159
4.4.1 Description .................................................................................................................................159
4.4.2 Safety instructions for Power Modules chassis format ..............................................................159
4.4.3 Interface description...................................................................................................................160
4.4.3.1 Overview ....................................................................................................................................160
4.4.3.2 Connection example ..................................................................................................................162
4.4.3.3 Terminal Block X9......................................................................................................................163
4.4.3.4 DCPS, DCNS connection for a dv/dt filter .................................................................................163
4.4.3.5 X41 EP terminal / temperature sensor connection ....................................................................164
4.4.3.6 X42 terminal strip .......................................................................................................................165
4.4.3.7 X46 Brake control and monitoring..............................................................................................166
4.4.3.8 DRIVE-CLiQ interface X400-X402.............................................................................................166
4.4.3.9 Meaning of the LEDs on the Power Module ..............................................................................167
4.4.4 Dimension drawings...................................................................................................................168
4.4.5 Electrical connection ..................................................................................................................170
4.4.6 Technical data............................................................................................................................172
4.4.6.1 Characteristics ...........................................................................................................................174
5 DC link components ............................................................................................................................ 179
5.1 Blocksize ....................................................................................................................................179
5.1.1 Braking resistors ........................................................................................................................179
5.1.1.1 Description .................................................................................................................................179
5.1.1.2 Safety instructions for blocksize braking resistors.....................................................................179
5.1.1.3 Connection examples ................................................................................................................181
5.1.1.4 Dimension drawings...................................................................................................................182
5.1.1.5 Installation ..................................................................................................................................186
5.1.1.6 Technical data............................................................................................................................187
5.2 Chassis ......................................................................................................................................192
5.2.1 Braking Modules ........................................................................................................................192
5.2.1.1 Description .................................................................................................................................192
5.2.1.2 Safety instructions for Braking Modules chassis format ............................................................193
5.2.1.3 Braking Module for frame size FX..............................................................................................194
5.2.1.4 Braking Module for frame size GX.............................................................................................195
5.2.1.5 Connection example ..................................................................................................................196
5.2.1.6 Braking resistor connection X1 ..................................................................................................197
5.2.1.7 X21 digital inputs/outputs...........................................................................................................197
5.2.1.8 S1 Threshold switch...................................................................................................................198
5.2.1.9 Installing a Braking Module in a Power Module, frame size FX ................................................199
5.2.1.10 Installing a Braking Module in a Power Module, frame size GX................................................201
5.2.1.11 Technical data............................................................................................................................203
5.2.2 Braking resistors ........................................................................................................................204
5.2.2.1 Description .................................................................................................................................204
5.2.2.2 Safety instructions for braking resistors chassis format.............................................................204
5.2.2.3 Dimension drawing ....................................................................................................................207
5.2.2.4 Electrical connection ..................................................................................................................208
5.2.2.5 Technical data............................................................................................................................208
6 Motor-side power components ............................................................................................................ 211
6.1 Blocksize ....................................................................................................................................211
6.1.1 Motor reactors............................................................................................................................211
6.1.1.1 Description .................................................................................................................................211
6.1.1.2 Safety instructions for motor reactors ........................................................................................211

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6.1.1.3 Dimension drawings.................................................................................................................. 213
6.1.1.4 Mounting.................................................................................................................................... 221
6.1.1.5 Electrical connection ................................................................................................................. 227
6.1.1.6 Technical data........................................................................................................................... 228
6.2 Chassis...................................................................................................................................... 231
6.2.1 Motor reactors ........................................................................................................................... 231
6.2.1.1 Description ................................................................................................................................ 231
6.2.1.2 Safety instructions for motor reactors ....................................................................................... 231
6.2.1.3 Dimension drawing.................................................................................................................... 233
6.2.1.4 Technical data........................................................................................................................... 234
6.2.2 Sinusoidal filter.......................................................................................................................... 235
6.2.2.1 Description ................................................................................................................................ 235
6.2.2.2 Safety instructions for sine-wave filter chassis format .............................................................. 235
6.2.2.3 Dimension drawing.................................................................................................................... 237
6.2.2.4 Technical data........................................................................................................................... 238
6.2.3 dv/dt filter plus Voltage Peak Limiter......................................................................................... 239
6.2.3.1 Description ................................................................................................................................ 239
6.2.3.2 Safety instructions for du/dt filter plus Voltage Peak Limiter..................................................... 239
6.2.3.3 Interface description.................................................................................................................. 242
6.2.3.4 Connecting the dv/dt filter plus Voltage Peak Limiter ............................................................... 243
6.2.3.5 Dimension drawing, dv/dt reactor ............................................................................................. 244
6.2.3.6 Dimension drawing of the voltage peak limiter ......................................................................... 245
6.2.3.7 Technical data........................................................................................................................... 246
6.2.4 dv/dt filter compact plus Voltage Peak Limiter.......................................................................... 247
6.2.4.1 Description ................................................................................................................................ 247
6.2.4.2 Safety instructions for du/dt filter compact plus Voltage Peak Limiter...................................... 247
6.2.4.3 Interface description.................................................................................................................. 251
6.2.4.4 Connecting the dv/dt filter compact plus Voltage Peak Limiter................................................. 252
6.2.4.5 Dimension drawing of dv/dt filter compact plus Voltage Peak Limiter ...................................... 253
6.2.4.6 Technical data........................................................................................................................... 255
7 Control Units, Control Unit Adapters and operating components...........................................................257
7.1 Introduction................................................................................................................................ 257
7.1.1 Control Units ............................................................................................................................. 257
7.1.2 Control Unit Adapter.................................................................................................................. 259
7.2 Safety instructions for Control Units and Control Unit Adapters............................................... 260
7.3 Control Unit CU310-2 PN (PROFINET) .................................................................................... 262
7.3.1 Description ................................................................................................................................ 262
7.3.2 Interface description.................................................................................................................. 263
7.3.2.1 Overview ................................................................................................................................... 263
7.3.2.2 X22 serial interface (RS232)..................................................................................................... 264
7.3.2.3 X23 HTL/TTL/SSI encoder interface......................................................................................... 265
7.3.2.4 X100 DRIVE-CLiQ interface...................................................................................................... 268
7.3.2.5 X120 digital inputs (fail-safe)/EP terminal/temperature sensor................................................. 269
7.3.2.6 X121 digital inputs/outputs ........................................................................................................ 271
7.3.2.7 X124 Electronics power supply................................................................................................. 273
7.3.2.8 X127 LAN (Ethernet)................................................................................................................. 274
7.3.2.9 X130 digital input (fail safe) digital output ................................................................................. 275
7.3.2.10 X131 digital inputs/outputs and analog input ............................................................................ 276
7.3.2.11 X150 P1/P2 PROFINET............................................................................................................ 278
7.3.2.12 Measuring sockets .................................................................................................................... 279

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7.3.2.13 S5 DIP switch.............................................................................................................................279
7.3.2.14 DIAG button ...............................................................................................................................279
7.3.2.15 RESET button ............................................................................................................................279
7.3.2.16 Memory card ..............................................................................................................................280
7.3.3 Connection examples ................................................................................................................281
7.3.4 Meaning of the LEDs .................................................................................................................283
7.3.4.1 Function of the LEDs .................................................................................................................283
7.3.4.2 Behavior of the LEDs during booting .........................................................................................284
7.3.4.3 Behavior of the LEDs in the operating state ..............................................................................285
7.3.5 Dimension drawing ....................................................................................................................286
7.3.6 Technical data............................................................................................................................287
7.4 Control Unit CU310-2 DP (PROFIBUS).....................................................................................288
7.4.1 Description .................................................................................................................................288
7.4.2 Interface description...................................................................................................................289
7.4.2.1 Overview ....................................................................................................................................289
7.4.2.2 X21 PROFIBUS .........................................................................................................................290
7.4.2.3 PROFIBUS address switch........................................................................................................291
7.4.2.4 X22 serial interface (RS232)......................................................................................................292
7.4.2.5 X23 HTL/TTL/SSI encoder interface..........................................................................................293
7.4.2.6 X100 DRIVE-CLiQ interface ......................................................................................................296
7.4.2.7 X120 digital inputs (fail-safe)/EP terminal/temperature sensor .................................................297
7.4.2.8 X121 digital inputs/outputs.........................................................................................................299
7.4.2.9 X124 Electronics power supply..................................................................................................301
7.4.2.10 X127 LAN (Ethernet)..................................................................................................................302
7.4.2.11 X130 digital input (fail safe) digital output ..................................................................................303
7.4.2.12 X131 digital inputs/outputs and analog input .............................................................................304
7.4.2.13 Measuring sockets .....................................................................................................................306
7.4.2.14 S5 DIP switch.............................................................................................................................306
7.4.2.15 DIAG button ...............................................................................................................................306
7.4.2.16 RESET button ............................................................................................................................306
7.4.2.17 Memory card ..............................................................................................................................307
7.4.3 Connection examples ................................................................................................................308
7.4.4 Meaning of the LEDs .................................................................................................................310
7.4.4.1 Function of the LEDs .................................................................................................................310
7.4.4.2 Behavior of the LEDs during booting .........................................................................................311
7.4.4.3 Behavior of the LEDs in the operating state ..............................................................................312
7.4.5 Dimension drawing ....................................................................................................................314
7.4.6 Technical data............................................................................................................................315
7.5 Control Unit Adapter CUA31......................................................................................................316
7.5.1 Description .................................................................................................................................316
7.5.2 Interface description...................................................................................................................317
7.5.2.1 Overview ....................................................................................................................................317
7.5.2.2 X200-X202 DRIVE-CLiQ interfaces...........................................................................................318
7.5.2.3 X210 EP terminal / temperature sensor.....................................................................................319
7.5.2.4 X224 electronics power supply ..................................................................................................320
7.5.3 Connection example ..................................................................................................................320
7.5.4 Meaning of the LEDs .................................................................................................................321
7.5.5 Dimension drawing ....................................................................................................................321
7.5.6 Technical data............................................................................................................................322
7.6 Control Unit Adapter CUA32......................................................................................................323
7.6.1 Description .................................................................................................................................323

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7.6.2 Interface description.................................................................................................................. 324
7.6.2.1 Overview ................................................................................................................................... 324
7.6.2.2 X200-X202 DRIVE-CLiQ interfaces .......................................................................................... 325
7.6.2.3 X210 EP terminal / temperature sensor.................................................................................... 326
7.6.2.4 X220 HTL/TTL/SSI encoder interface....................................................................................... 327
7.6.2.5 X224 electronics power supply ................................................................................................. 329
7.6.3 Connection example ................................................................................................................. 329
7.6.4 Meaning of the LEDs................................................................................................................. 330
7.6.5 Dimension drawing.................................................................................................................... 331
7.6.6 Technical data........................................................................................................................... 331
7.7 Mounting Control Units and Control Unit Adapters................................................................... 332
7.8 Basic Operator Panel BOP20 ................................................................................................... 334
7.8.1 Description ................................................................................................................................ 334
7.8.2 Interface description.................................................................................................................. 334
7.8.3 Mounting.................................................................................................................................... 337
8 Supplementary system components and encoder system integration ...................................................341
8.1 Sensor Modules ........................................................................................................................ 341
8.1.1 Safety instructions for Sensor Modules Cabinet-Mounted........................................................ 341
8.1.2 Sensor Module Cabinet-Mounted SMC10 ................................................................................ 343
8.1.2.1 Description ................................................................................................................................ 343
8.1.2.2 Interface description.................................................................................................................. 343
8.1.2.3 Meaning of the LEDs................................................................................................................. 347
8.1.2.4 Dimension drawing.................................................................................................................... 348
8.1.2.5 Mounting.................................................................................................................................... 349
8.1.2.6 Technical data........................................................................................................................... 350
8.1.3 Sensor Module Cabinet-Mounted SMC20 ................................................................................ 352
8.1.3.1 Description ................................................................................................................................ 352
8.1.3.2 Interface description.................................................................................................................. 352
8.1.3.3 Meaning of the LEDs................................................................................................................. 356
8.1.3.4 Dimension drawing.................................................................................................................... 357
8.1.3.5 Mounting.................................................................................................................................... 358
8.1.3.6 Technical data........................................................................................................................... 359
8.1.4 Sensor Module Cabinet-Mounted SMC30 ................................................................................ 360
8.1.4.1 Description ................................................................................................................................ 360
8.1.4.2 Interface description.................................................................................................................. 360
8.1.4.3 Connection examples................................................................................................................ 367
8.1.4.4 Meaning of the LEDs................................................................................................................. 369
8.1.4.5 Dimension drawing.................................................................................................................... 370
8.1.4.6 Mounting.................................................................................................................................... 371
8.1.4.7 Protective conductor connection and shield support ................................................................ 372
8.1.4.8 Technical data........................................................................................................................... 373
8.2 Option module Safe Brake Relay.............................................................................................. 378
8.2.1 Introduction................................................................................................................................ 378
8.2.2 Safety instructions for Safe Brake Relays................................................................................. 378
8.2.3 Interface description.................................................................................................................. 379
8.2.3.1 Overview ................................................................................................................................... 379
8.2.3.2 X524 electronics power supply ................................................................................................. 379
8.2.3.3 Brake connection ...................................................................................................................... 380
8.2.4 Connection example ................................................................................................................. 380
8.2.5 Dimension drawing.................................................................................................................... 381

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8.2.6 Mounting ....................................................................................................................................382
8.2.7 Technical data............................................................................................................................383
8.3 Safe Brake Adapter optional module .........................................................................................384
8.3.1 Description .................................................................................................................................384
8.3.2 Safety instructions for Safe Brake Adapters ..............................................................................385
8.3.3 Interface description...................................................................................................................386
8.3.3.1 Overview ....................................................................................................................................386
8.3.3.2 X11 interface to the Control Interface Module ...........................................................................387
8.3.3.3 X12 230 V AC power supply......................................................................................................387
8.3.3.4 X14 load connection ..................................................................................................................388
8.3.3.5 X15 fast de-energization ............................................................................................................388
8.3.4 Connection example ..................................................................................................................389
8.3.5 Dimension drawing ....................................................................................................................389
8.3.6 Mounting ....................................................................................................................................390
8.3.7 Technical data............................................................................................................................390
9 Accessories ........................................................................................................................................ 391
9.1 DRIVE-CLiQ cabinet bushing ....................................................................................................391
9.1.1 Description .................................................................................................................................391
9.1.2 Interface description...................................................................................................................392
9.1.2.1 Overview ....................................................................................................................................392
9.1.3 Dimension drawings...................................................................................................................393
9.1.4 Installation ..................................................................................................................................394
9.1.4.1 DRIVE-CLiQ cabinet bushing for cables with DRIVE-CLiQ connectors....................................394
9.1.4.2 DRIVE-CLiQ cabinet bushing for cables with M12 plug/socket.................................................396
9.1.5 Technical data............................................................................................................................397
9.2 DRIVE-CLiQ coupling ................................................................................................................398
9.2.1 Description .................................................................................................................................398
9.2.2 Interface description...................................................................................................................398
9.2.2.1 Overview ....................................................................................................................................398
9.2.3 Dimension drawing ....................................................................................................................399
9.2.4 Mounting ....................................................................................................................................399
9.2.5 Technical data............................................................................................................................400
9.3 Mounting frame ..........................................................................................................................401
9.3.1 Description .................................................................................................................................401
9.3.2 Dimension drawings...................................................................................................................402
9.3.3 Mounting ....................................................................................................................................403
9.4 Shield connection kit ..................................................................................................................404
9.4.1 Description .................................................................................................................................404
9.4.2 Dimension drawings...................................................................................................................405
9.4.2.1 Shield connection kits ................................................................................................................405
9.4.2.2 Blocksize Power Modules with shield connection kit.................................................................407
9.4.3 Mounting ....................................................................................................................................412
9.4.3.1 PM340 Blocksize Power Modules..............................................................................................412
9.4.3.2 Power cable connection.............................................................................................................415
10 Cabinet design and EMC for components, Blocksize format ................................................................ 417
10.1 General information ...................................................................................................................417
10.2 Safety instructions for control panel manufacturing...................................................................418

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10.3 Notes on electromagnetic compatibility (EMC)......................................................................... 419
10.4 Cable shielding and routing....................................................................................................... 420
10.5 24 V DC Supply Voltage ........................................................................................................... 422
10.5.1 General...................................................................................................................................... 422
10.5.2 Overcurrent protection .............................................................................................................. 423
10.5.3 Overvoltage protection .............................................................................................................. 424
10.5.4 Typical 24 V current consumption of the components.............................................................. 425
10.5.5 Selecting power supply units .................................................................................................... 426
10.6 Connection Methods ................................................................................................................. 427
10.6.1 DRIVE-CLiQ signal cables........................................................................................................ 427
10.6.1.1 Overview ................................................................................................................................... 427
10.6.1.2 DRIVE-CLiQ signal cables without 24 V DC cores ................................................................... 428
10.6.1.3 DRIVE-CLiQ signal cables MOTION-CONNECT with DRIVE-CLiQ connectors...................... 429
10.6.1.4 MOTION-CONNECT DRIVE-CLiQ signal cables with DRIVE-CLiQ connector and M12
socket........................................................................................................................................ 429
10.6.1.5 Comparison of DRIVE-CLiQ signal cables ............................................................................... 431
10.6.1.6 Combined use of MOTION-CONNECT 500 and MOTION-CONNECT 800PLUS ................... 432
10.6.2 Power cables for motors ........................................................................................................... 433
10.6.2.1 Configuring the cable length ..................................................................................................... 433
10.6.2.2 Comparison of MOTION-CONNECT power cables .................................................................. 434
10.6.3 Current-carrying capacity and derating factors for power cables and signal cables ................ 435
10.6.4 Spring-loaded terminals ............................................................................................................ 437
10.6.5 Screw terminals......................................................................................................................... 437
10.7 Protective connection and equipotential bonding ..................................................................... 438
10.8 Arrangement of components and equipment............................................................................ 440
10.8.1 General...................................................................................................................................... 440
10.8.2 Mounting.................................................................................................................................... 441
10.9 Information on control cabinet cooling ...................................................................................... 443
10.9.1 General...................................................................................................................................... 443
10.9.2 Ventilation.................................................................................................................................. 445
10.9.3 Power loss of components in rated operation........................................................................... 447
10.9.3.1 General...................................................................................................................................... 447
10.9.3.2 Power loss of Control Units, Control Unit Adapters and Sensor Modules................................ 447
10.9.3.3 Power loss for line reactors and line filters ............................................................................... 448
10.9.3.4 Power loss for Power Modules ................................................................................................. 450
11 Service and maintenance.....................................................................................................................453
11.1 Safety instructions for service and maintenance ...................................................................... 453
11.2 Service and maintenance for components, Blocksize format ................................................... 454
11.2.1 Replacing hardware components ............................................................................................. 454
11.2.2 Replacing the fan CU310-2 DP and CU310-2 PN .................................................................... 454
11.2.3 Replacing the fan on the PM240-2 ........................................................................................... 456
11.2.4 Replacing the fan on the PM340............................................................................................... 457
11.3 Service and maintenance for Chassis format components ...................................................... 463
11.3.1 Maintenance.............................................................................................................................. 463
11.3.2 Installation equipment ............................................................................................................... 465
11.3.3 Replacing components.............................................................................................................. 466
11.3.3.1 Replacing the Powerblock, Power Module, frame size FX ....................................................... 466

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11.3.3.2 Replacing the Powerblock, Power Module, frame size GX .......................................................469
11.3.3.3 Replacing the Control Interface Module, Power Module, frame size FX...................................472
11.3.3.4 Replacing the Control Interface Module, Power Module, frame size GX ..................................474
11.3.3.5 Replacing the fan, Power Module, frame size FX......................................................................476
11.3.3.6 Replacing the fan, Power Module, frame size GX .....................................................................478
11.4 Forming the DC link capacitors..................................................................................................480
11.5 Spare parts.................................................................................................................................484
11.6 Recycling and disposal ..............................................................................................................484
A Appendix............................................................................................................................................. 485
A.1 List of abbreviations ...................................................................................................................485
A.2 Documentation overview............................................................................................................494
Index................................................................................................................................................... 495

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20 Manual, (GH6), 04/2014, 6SL3097-4AL00-0BP4