Siemens SINAMICS G120P Assembly instructions

Answers for industry.
SINAMICS G120P
Power Module PM230, IP20 / Push through
Hardware Installation Manual · 03/2012
SINAMICS

Power Module PM230, IP20 / Push
through
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SINAMICS
SINAMICS G120P
Power Module PM230, IP20 / Push
through
Hardware Installation Manual
03/2012 Edition
03/2012
A5E03448282B AA
Introduction
1
Safety notes
2
Installing/Mounting
3
Connecting
4
Service and maintenance
5
Technical specifications
6
Accessories
7
Appendix
A

Legal information
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
with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.
CAUTION
without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.
NOTICE
indicates that an unintended result or situation can occur if the relevant information is not taken into account.
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.
Siemens AG
Industry Sector
Postfach 48 48
90026 NÜRNBERG
GERMANY
A5E03448282B AA
Ⓟ 03/2012 Technical data subject to change
Copyright © Siemens AG 2010,
2011.
All rights reserved

Power Module PM230, IP20 / Push through
Hardware Installation Manual, 03/2012, A5E03448282B AA 5
Table of contents
1 Introduction................................................................................................................................................ 7
2 Safety notes............................................................................................................................................... 9
3 Installing/Mounting................................................................................................................................... 13
3.1 Installation conditions...................................................................................................................13
3.2 Power losses and air cooling requirements.................................................................................14
3.3 Mounting the Power Modules ......................................................................................................16
3.3.1 Build-in Power Modules - IP20.....................................................................................................16
3.3.2 Push-through Power Modules - IP54...........................................................................................19
3.4 Control Unit installation ................................................................................................................22
4 Connecting .............................................................................................................................................. 23
4.1 Mains and Motor Connection.......................................................................................................24
4.1.1 Motor cable length .......................................................................................................................25
4.1.2 Motor connection .........................................................................................................................25
4.1.3 Mains and Motor Terminals, FSA ... FSC ....................................................................................26
4.1.4 Mains and Motor Terminals, FSD ... FSF ....................................................................................26
4.2 EMC compliant connection ..........................................................................................................27
4.2.1 Avoiding electromagnetic interference.........................................................................................27
4.2.2 EMC-compliant cabinet design ....................................................................................................27
4.2.3 Cabinet design .............................................................................................................................28
4.2.4 Cabling.........................................................................................................................................29
4.2.5 Equipotential bonding ..................................................................................................................31
4.2.6 EMC-compliant wiring ..................................................................................................................34
5 Service and maintenance ........................................................................................................................ 37
5.1 Maintenance.................................................................................................................................37
5.2 Replacing the cooling fan.............................................................................................................38
6 Technical specifications........................................................................................................................... 41
6.1 Specifications...............................................................................................................................44
6.2 Derating data................................................................................................................................50
6.2.1 Operational temperature and temperature derating ....................................................................50
6.2.2 Operational altitude and altitude deratings ..................................................................................50
6.2.3 Operational power and voltage derating......................................................................................51
6.2.4 Current reduction depending on pulse frequency........................................................................51
6.3 Permissible shock and vibration values.......................................................................................52
7 Accessories ............................................................................................................................................. 53
7.1 Mounting Frames .........................................................................................................................53

Table of contents
Power Module PM230, IP20 / Push through
6 Hardware Installation Manual, 03/2012, A5E03448282B AA
A Appendix.................................................................................................................................................. 55
A.1 Further information on your converter......................................................................................... 55
A.1.1 Manuals for your inverter ............................................................................................................ 55
A.1.2 Configuring support..................................................................................................................... 56
A.1.3 Product Support .......................................................................................................................... 56
A.2 Electromagnetic compatibility ..................................................................................................... 57
A.2.1 Definition of the EMC Environment and Categories ................................................................... 57
A.2.2 Compliance with EMC Environment and Categories.................................................................. 58
A.2.3 EMC limit values in South Korea ................................................................................................ 59
A.3 Standards.................................................................................................................................... 60
A.4 Abbreviations .............................................................................................................................. 61
Index........................................................................................................................................................ 63

Power Module PM230, IP20 / Push through
Hardware Installation Manual, 03/2012, A5E03448282B AA 7
Introduction 1
Power Modules PM230
The Power Module PM230 is part of the
modular inverter family SINAMICS G120.
PM230 Power Modules, are focused on the
HVAC industry sector especially for pump
and fan applications.
The Power Modules are available with class-
A filter or unfiltered in a rated-power range
from 0.37 kW … 90 kW and a line voltage
range from 3 AC 380 V … 480 V.
In the design of the Power Modules the
following power distribution systems have
been considered:
TN
TT (only unfiltered Power Modules)
IT (only unfiltered Power Modules)
Note:
The sign " " is equivalent to the designation
"PE".
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Block diagram PM230
The Power Modules can be used with the following Control Units including all communication
variants with firmware version 4.4 or higher.
● CU230P-2
● CU240B-2
● CU240E-2
Operation with any other Control Units as listed above is not permitted.
Note
Failsafe functions are not supported by the PM230.

Introduction
Power Module PM230, IP20 / Push through
8 Hardware Installation Manual, 03/2012, A5E03448282B AA

Power Module PM230, IP20 / Push through
Hardware Installation Manual, 03/2012, A5E03448282B AA 9
Safety notes 2
It has to be ensured by the machine manufacturer, that the line-side overcurrent protection
equipment interrupts within 5 s (immovable equipment and modules in immovable
equipment) in the case of minimum fault current (current on complete insulation failure to
accessible conductive parts that are not live during operation and maximum current loop
resistance).
The machine manufacturer must ensure that the voltage drop between the main power
supply and the power drive system, during operation, does not exceed 1 % (UK < 1 %).
General
WARNING
This equipment controls potentially dangerous rotating mechanical parts.
Protection in case of direct contact by means of voltages < 60 V (PELV = Protective Extra
Low Voltage acc. to EN 61800-5-1) is only permissible in areas with equipotential bonding
and in dry indoor rooms. If these conditions are not fulfilled, other protective measures
against electric shock must be applied e.g. protective insulation.
The converter must always be grounded.
Install the converter on a metal mounting plate in a control cabinet. The mounting plate has
to be unpainted and with a good electrical conductivity.
It is strictly prohibited for any mains disconnection to be performed on the motor-side of the
system, if the converter is in operation and the output current is not zero.
Take particular notice of the general and regional installation and safety regulations
regarding work on dangerous voltage installations (e.g. 61800-5-1) as well as the relevant
regulations regarding the correct use of tools and personal protective equipment (PPE).
CAUTION
Static discharges on surfaces or interfaces (e.g. terminal or connector pins) can cause
malfunctions or defects. Therefore, when working with converters or converter components,
ESD protective measures should be observed.
DANGER
Dangerous voltage!
Hazardous voltage is still present for up to 5 minutes after the power supply has been
switched off. Do not to carry out any installation work before this time has expired!

Safety notes
Power Module PM230, IP20 / Push through
10 Hardware Installation Manual, 03/2012, A5E03448282B AA
WARNING
Protective earthing conductor current
As the earth leakage for the inverter can be greater than AC 3.5 mA, a fixed earth
connection is required and the minimum size of the protective earth conductor shall comply
with the local safety regulations for high leakage current equipment.
The inverter can cause a DC current in the protective earthing conductor. Where a residual
current-operated protective (RCD) or monitoring (RCM) device is used for protection in
case of direct or indirect contact, only an RCD or RCM of Type B superresistant is allowed
on the supply side of the inverter.
Transport and storage
CAUTION
Don't drop the converter or converter components during transport and storage. Protect the
equipment from water (rainfall) and excessive temperatures.
Installation and Commissioning
WARNING
Wherever faults occurring in the control equipment can lead to substantial material damage
or even grievous bodily injury (that is, potentially dangerous faults), additional external
precautions must be taken or facilities provided to ensure or enforce safe operation, even
when a fault occurs (e.g. independent limit switches, mechanical interlocks, etc.).
Operation
DANGER
Operating the converter outside the scope of the specification given in the technical
specifications may cause malfunction or damage to the converter components. In
exceptional cases there is the potential to cause overheating, danger of fire, damage to
property, personal injury or loss of life.
WARNING
Emergency stop facilities according to EN 60204, IEC 204 (VDE 0113) must remain
operative in all operating modes of the control equipment. Any disengagement of the
emergency stop facility must not lead to an uncontrolled or an undefined restart of the
equipment.

Safety notes
Power Module PM230, IP20 / Push through
Hardware Installation Manual, 03/2012, A5E03448282B AA 11
WARNING
Use of mobile radio devices (e.g. telephones, walkie-talkies) in the immediate vicinity of the
devices (< 1.8 m) can interfere with the functioning of the equipment.
WARNING
Filtered drives can only be used on power systems with grounded neutral point.
WARNING
During operation and for a short time after switching-off the converter, the surfaces of the
converter can reach a high temperature. Avoid coming into direct contact with the converter
surface.
CAUTION
This equipment is suitable for use in a power system up to 65,000 symmetrical amperes
(rms), for the maximum rated voltage + 10 % when protected by an appropriate standard
fuse (refer to the catalogue for the type of fuse).
Repair
WARNING
Repairs on equipment may only be carried out by Siemens Service, by repair centers
authorized by Siemens or by authorized personnel who are thoroughly acquainted with all
the warnings and operating procedures contained in this manual.
Any defective parts or components must be replaced using parts contained in the relevant
spare parts list.
Dismantling and disposal
CAUTION
The packaging of the inverter is re-usable. Retain the packaging for future use.
Easy-to-release screw and snap connectors allow you to break the unit down into its
component parts. You can recycle these component parts, dispose of them in accordance
with local requirements or return them to the manufacturer.
Residual risks
The control and drive components of a power drive system (PDS) are approved for industrial
and commercial use in industrial line supplies. Their use in public line supplies requires a
different configuration and/or additional measures.

Safety notes
Power Module PM230, IP20 / Push through
12 Hardware Installation Manual, 03/2012, A5E03448282B AA
These components may only be operated in closed housings or in higher-level control
cabinets with protective covers that are closed, and when all of the protective devices are
used.
These components may only be handled by qualified and trained technical personnel who
are knowledgeable and observe all of the safety information and instructions on the
components and in the associated technical user documentation.
When carrying out a risk assessment of a machine in accordance with the EU Machinery
Directive, the machine manufacturer must consider the following residual risks associated
with the control and drive components of a PDS.
1. Unintentional movements of driven machine components during commissioning,
operation, maintenance, and repairs caused by, for example:
– Hardware defects and/or software errors in the sensors, controllers, actuators, and
connection technology
– Response times of the controller and drive
– Operating and/or ambient conditions not within the scope of the specification
– Condensation / conductive contamination
– Parameterization, programming, cabling, and installation errors
– Use of radio devices / cellular phones in the immediate vicinity of the controller
– External influences / damage
2. Exceptional temperatures as well as emissions of noise, particles, or gas caused by, for
example:
– Component malfunctions
– Software errors
– Operating and/or ambient conditions not within the scope of the specification
– External influences / damage
3. Hazardous shock voltages caused by, for example:
– Component malfunctions
– Influence of electrostatic charging
– Induction of voltages in moving motors
– Operating and/or ambient conditions not within the scope of the specification
– Condensation / conductive contamination
– External influences / damage
4. Electrical, magnetic and electromagnetic fields generated in operation that can pose a
risk to people with a pacemaker, implants or metal replacement joints, etc. if they are too
close.
5. Release of environmental pollutants or emissions as a result of improper operation of the
system and/or failure to dispose of components safely and correctly.

Power Module PM230, IP20 / Push through
Hardware Installation Manual, 03/2012, A5E03448282B AA 13
Installing/Mounting 3
3.1 Installation conditions
General rules for the environmental protection of the Power Modules
To ensure that the power module is installed in the correct environmental conditions, please
ensure that you adhere to the following guidelines:
● The Power Modules are designed
– to be installed in an electrical cabinet
– with protection against the ingress of solid foreign objects ≥ 12.5 mm
– without protection against the ingress of water
Note
Push through units
The Power Module as a whole is IP20 rated.
If it is installed in a cabinet which is IP54 rated, the Push through units can maintain
the IP54 protection rating of the cabinet, if the appropriate seals are used when
mounting the rear of the Power Module through the back of the cabinet.
According to UL the Push through units only fulfill the requirements of an open type
component.
● Furthermore take care of the following conditions:
– Keep it free from dust and dirt
– Keep it away from water, solvents and chemicals
Take care to site it away from potential water hazards, for example, do not install it
beneath pipes that are subject to condensation. Avoid installing it where excessive
humidity and condensation may occur
– Keep it within the maximum and minimum operating temperatures
– Ensure that the correct level of ventilation and air flow is provided
– Ensure that earthing and grounding practices for each Power Module and the cabinet
follows the guidelines given in section Connecting (Page 23).
The Power Module must only be installed in vertical direction as shown in the figure.

Installing/Mounting
3.2 Power losses and air cooling requirements
Power Module PM230, IP20 / Push through
14 Hardware Installation Manual, 03/2012, A5E03448282B AA
WARNING
To ensure the safe operation of the equipment, it must be installed and commissioned by
qualified personnel in full compliance with the warnings laid down in this manual.
Take particular note of the general and regional installation and safety regulations
regarding work on dangerous voltage installation (e.g. EN 61800-5-1) as well as the
relevant regulations regarding the correct use of tools and personal protective equipment
(PPE).
3.2 Power losses and air cooling requirements
Cooling requirements
Depending on the power losses of the various components a specific cooling air flow is
required to protect the components from overheating. The following procedure shows how to
calculate the required air flow.
1. Add the power losses of the respective components
2. Calculate the airflow required, using the formula
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3. Ensure that no equipment is installed that has a negative influence on the flow of the
cooling air.
4. Ensure that the cooling vents in the Power Module are positioned correctly to allow the
free movement of air.

Installing/Mounting
3.2 Power losses and air cooling requirements
Power Module PM230, IP20 / Push through
Hardware Installation Manual, 03/2012, A5E03448282B AA 15
5. Avoid short circuits of the cooling air using air barriers, if necessary
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6. Provide an adequate cabinet with sufficient ventilation and suitable air filters.
The power losses and the required air flow of the Power Modules are given in the section
Specifications (Page 44) of this Manual. The maximum power losses of the CU are less than
0.04 kW.
The values are valid for:
● Rated output current
● 50 Hz output frequency
● 4 kHz pulse frequency
If you use Push through units, you should calculate with losses of 0.02 kW inside the
cabinet. Take care that the losses outside the cabinet do not cause overheating of the Power
Modules.
For other components like reactors or filters use the values given by the manufacturer and
calculate the required airflow using the formula given in this section.

Installing/Mounting
3.3 Mounting the Power Modules
Power Module PM230, IP20 / Push through
16 Hardware Installation Manual, 03/2012, A5E03448282B AA
3.3 Mounting the Power Modules
The Power Modules are designed to be mounted in accordance with the dimensional
drawings, in a cabinet using bolts, nuts and washers.
Note
EMC
Due to EMC, it is recomended to fix the inverter on an electrically conductive cabinet wall.
In case of a Push through unit the electrical connection is achieved by fixing the Power
Module with the recommended bolts and screws on the electrical conductive cabinet wall.
Dimensions drawings
The dimension drawings shown in the following figures are not true to scale.
3.3.1 Build-in Power Modules - IP20
Drill patterns, dimensions and distances of Power Modules PM230, IP20
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Installing/Mounting
3.3 Mounting the Power Modules
Power Module PM230, IP20 / Push through
Hardware Installation Manual, 03/2012, A5E03448282B AA 17
Table 3- 1 Dimensions and distances
Dimensions (mm) Distances (mm)3) Frame Size
Height1) Width Depth 2) a b c Waste
heat
Cooling
air
FSA filtered /unfiltered 196 73 165 186 62.3 6 80 100
FSB filtered /unfiltered 292 100 165 281 80 6 80 100
FSC filtered /unfiltered 355 140 165 343 120 6 80 100
FSD unfiltered 419 275 204 325 235 11 300 300
FSD filtered 512 275 204 419 235 11 300 300
FSE unfiltered 499 275 204 405 235 11 300 300
FSE filtered 635 275 204 541 235 11 300 300
FSF unfiltered 634 350 316 598 300 11 350 350
FSF filtered 934 350 316 899 300 11 350 350
Fixing: FSA/FSB: Screws M4, 2,5 Nm
FSC: Screws M5, 3 Nm
FSD/FSE: Screws M6, 6 Nm
FSF: Screws M8, 13 Nm
1) Using a screen termination kit:
FSA: + 80 mm; FSB: + 78 mm; FSC: + 77 mm; FSD, FSE, FSF: + 123 mm
2) plus 58 mm using a CU230, plus 40 mm using a CU240,
plus another 10 mm or 25 mm using a BOP-2 or an IOP as Operator Panel (OP)
3) The Power Modules can be mounted side-by-side. Due to tolerance reasons, we recommend a lateral distance of about
1 mm
Mounting the shielding plate
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Figure 3-2 Mounting the shielding plate, FSA … FSC

Installing/Mounting
3.3 Mounting the Power Modules
Power Module PM230, IP20 / Push through
18 Hardware Installation Manual, 03/2012, A5E03448282B AA
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Figure 3-3 Mounting the shielding Plate, FSD ... FSF

Installing/Mounting
3.3 Mounting the Power Modules
Power Module PM230, IP20 / Push through
Hardware Installation Manual, 03/2012, A5E03448282B AA 19
3.3.2 Push-through Power Modules - IP54
Mounting Frame
It is recommended that the optional mounting frame is used to
install the Push through unit in a cabinet. The mounting frame
contains the necessary seals and frame to maintain an IP54
rating. If the Power Module is mounted without using the
optional mounting frame, it is the user's responsibility to ensure
the correct IP protection rating is reached.
Mounting the Inverter with Mounting Frame
1. Prepare the cut-out and the fixing holes for the Power
Module and the mounting frame in accordance with the
dimensional drawing of the Mounting Frame.
2. Apply the mounting frame to the rear of the cabinet wall and
fix it by hand into the cabinet using the appropriate bolts.
3. Attach the gasket on the inside surface of the cabinet.
4. Attach the inverter and fix it first by hand with all fixing
screws.
5. Tighten the screws with a torque of 3 Nm.
6. To fulfill the EMC requirements it is essential that the inside
cabinet wall is bare metal
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Installing/Mounting
3.3 Mounting the Power Modules
Power Module PM230, IP20 / Push through
20 Hardware Installation Manual, 03/2012, A5E03448282B AA
Drill patterns, dimensions and distances of Power Modules PM230, PT
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