Siemens SINAMICS G130 User manual

Operating instructions · 03/2012
Braking Module / braking resistor
SINAMICS G130
SINAMICS
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Braking Module / braking resistor
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SINAMICS
SINAMICS G130
Braking Module / braking resistor
Operating Instructions
Control version V4.5
03/2012
A5E00331454A
Safety information
1
General
2
Mechanical installation
3
Connection
4
Maintenance and servicing
5
Technical specifications
6

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
A5E00331454A
Ⓟ 04/2012 Technical data subject to change
Copyright © Siemens AG 2012.
All rights reserved

Braking Module / braking resistor
Operating Instructions, 03/2012, A5E00331454A 3
Table of contents
1 Safety information...................................................................................................................................... 5
1.1 Warnings........................................................................................................................................5
1.2 Safety and application instructions ................................................................................................6
1.3 Components that can be destroyed by electrostatic discharge (ESD) ..........................................7
2 General...................................................................................................................................................... 9
2.1 Braking Module ..............................................................................................................................9
2.2 Braking resistor ............................................................................................................................11
3 Mechanical installation............................................................................................................................. 13
3.1 General ........................................................................................................................................13
3.2 Braking Modules: overview ..........................................................................................................14
3.3 Installing the Braking Module.......................................................................................................17
3.3.1 Installing the Braking Module in a Power Module, frame size FX ...............................................17
3.3.2 Installing the Braking Module in a Power Module frame size GX................................................20
3.3.3 Installing the Braking Module in a Power Module frame size HX................................................23
3.3.4 Installing the Braking Module in a Power Module frame size JX.................................................24
3.4 Installing the braking resistor .......................................................................................................25
4 Connection .............................................................................................................................................. 27
4.1 Cable lugs ....................................................................................................................................28
4.2 Connecting the Braking Module...................................................................................................29
4.3 Connecting the braking resistor ...................................................................................................32
4.4 Disabling the Vdc-max controller .................................................................................................33
5 Maintenance and servicing ...................................................................................................................... 35
6 Technical specifications........................................................................................................................... 37

Table of contents
Braking Module / braking resistor
4 Operating Instructions, 03/2012, A5E00331454A

Braking Module / braking resistor
Operating Instructions, 03/2012, A5E00331454A 5
Safety information 1
1.1 Warnings
WARNING
Hazardous voltages are present when electrical equipment is in operation.
Severe personal injury or substantial material damage may result if these warnings are not
observed.
Only qualified personnel are permitted to work on or around the equipment.
This personnel must be thoroughly familiar with all the warnings and maintenance
procedures described in these operating instructions.
The successful and safe operation of this device is dependent on correct transport, proper
storage and installation, as well as careful operation and maintenance.
National safety guidelines must be observed.
DANGER
Five safety rules
When carrying out any kind of work on electrical devices, the "five safety rules" according to
EN 50110 must always be observed:
1. Disconnect the system.
2. Protect against reconnection.
3. Make sure that the equipment is de-energized.
4. Ground and short-circuit.
5. Cover or enclose adjacent components that are still live.
NOTICE
For a UL-approved system use 60/75°C copper conductors only.

Safety information
1.2 Safety and application instructions
Braking Module / braking resistor
6 Operating Instructions, 03/2012, A5E00331454A
1.2 Safety and application instructions
DANGER
This equipment is used in industrial high-voltage installations. During operation, this
equipment contains live, bare parts. For this reason, they could cause severe injury or
significant material damage if the required covers are removed, if they are used or operated
incorrectly, or have not been properly maintained.
When the machines are used in non-industrial areas, the installation location must be
protected against unauthorized access (protective fencing, appropriate signs).
Prerequisites
Those responsible for protecting the plant must ensure the following:
● The basic planning work for the plant and the transport, assembly, installation,
commissioning, maintenance, and repair work is carried out by qualified personnel and/or
checked by experts responsible.
● The operating manual and machine documentation are always available.
● The technical specifications regarding the applicable installation, connection,
environmental, and operating conditions are always observed.
● The plant-specific assembly and safety guidelines are observed and personal protection
equipment is used.
● Unqualified personnel are forbidden from using these machines and working near them.
This operating manual is intended for qualified personnel and only contain information and
notes relating to the intended purpose of the machines.
The operating manual and machine documentation are written in different languages as
specified in the delivery contracts.
Note
We recommend engaging the support and services of your local Siemens service center for
all planning, installation, commissioning and maintenance work.

Safety information
1.3 Components that can be destroyed by electrostatic discharge (ESD)
Braking Module / braking resistor
Operating Instructions, 03/2012, A5E00331454A 7
1.3 Components that can be destroyed by electrostatic discharge (ESD)
CAUTION
The board contains components that can be destroyed by electrostatic discharge. These
components can be easily destroyed if not handled properly. If you do have to use
electronic boards, however, please observe the following:
•You should only touch electronic boards if absolutely necessary.
•When you touch boards, however, your body must be electrically discharged
beforehand.
•Boards must not come into contact with highly insulating materials (such as plastic
parts, insulated desktops, articles of clothing manufactured from man-made fibers).
•Boards must only be placed on conductive surfaces.
•Boards and components should only be stored and transported in conductive packaging
(such as metalized plastic boxes or metal containers).
•If the packaging material is not conductive, the boards must be wrapped with a
conductive packaging material (such as conductive foam rubber or household aluminum
foil).
The necessary ESD protective measures are clearly illustrated in the following diagram:
● a = conductive floor surface
● b = ESD table
● c = ESD shoes
● d = ESD overall
● e = ESD wristband
● f = cabinet ground connection
● g = contact with conductive flooring
g ga
b
e
d
c
d
a
c
d
b
c a
e
f
f f f f
6LWWLQJ 6WDQGLQJ 6WDQGLQJVLWWLQJ
Figure 1-1 ESD protective measures

Safety information
1.3 Components that can be destroyed by electrostatic discharge (ESD)
Braking Module / braking resistor
8 Operating Instructions, 03/2012, A5E00331454A

Braking Module / braking resistor
Operating Instructions, 03/2012, A5E00331454A 9
General 2
2.1 Braking Module
Description
A Braking Module (and an external braking resistor) is required in certain cases when the
drive is to be braked or brought to a standstill (e.g., EMERGENCY STOP category 1). The
Braking Module contains the power electronics and the associated Control Unit. The supply
voltage for the electronics is drawn from the DC link.
During operation, the DC link energy is converted to heat loss in an external braking resistor.
The Braking Module functions independently of the converter closed-loop controller. In the
case of Power Modules with frame sizes HX and JX, it is possible to operate several Braking
Modules in parallel in order to enhance performance. In this case, each Braking Module
must be fitted with its own braking resistor.
Structure
The Braking Module is inserted in a slot inside the Power Module, the fan of which ensures
forced cooling. The Braking Module is connected to the DC link by means of the busbar sets
and flexible cables, which are supplied as standard.

General
2.1 Braking Module
Braking Module / braking resistor
10 Operating Instructions, 03/2012, A5E00331454A
Assignment of Braking Module and Power Module
Table 2- 1 Assignment of Braking Module and Power Module
Power Module Rated Power
Module output
Suitable Braking Module Rated power
output of the
Braking Module
Suitable brake resistance
Line voltage 380 – 480 V 3 AC
6SL3310-1GE32-1AAx 110 kW 6SL3300-1AE31-3AA0 25 kW 6SL3000-1BE31-3AA0
6SL3310-1GE32-6AAx 132 kW 6SL3300-1AE31-3AA0 25 kW 6SL3000-1BE31-3AA0
6SL3310-1GE33-1AAx 160 kW 6SL3300-1AE32-5AA0 50 kW 6SL3000-1BE32-5AA0
6SL3310-1GE33-8AAx 200 kW 6SL3300-1AE32-5AA0 50 kW 6SL3000-1BE32-5AA0
6SL3310-1GE35-0AAx 250 kW 6SL3300-1AE32-5AA0 50 kW 6SL3000-1BE32-5AA0
6SL3310-1GE36-1AAx 315 kW 6SL3300-1AE32-5BA0 50 kW 6SL3000-1BE32-5AA0
6SL3310-1GE37-5AAx 400 kW 6SL3300-1AE32-5BA0 50 kW 6SL3000-1BE32-5AA0
6SL3310-1GE38-4AAx 450 kW 6SL3300-1AE32-5BA0 50 kW 6SL3000-1BE32-5AA0
6SL3310-1GE41-0AAx 560 kW 6SL3300-1AE32-5BA0 50 kW 6SL3000-1BE32-5AA0
Line voltage 500 – 600 V 3 AC
6SL3310-1GF31-8AAx 110 kW 6SL3300-1AF32-5AA0 50 kW 6SL3000-1BF32-5AA0
6SL3310-1GF32-2AAx 132 kW 6SL3300-1AF32-5AA0 50 kW 6SL3000-1BF32-5AA0
6SL3310-1GF32-6AAx 160 kW 6SL3300-1AF32-5AA0 50 kW 6SL3000-1BF32-5AA0
6SL3310-1GF33-3AAx 200 kW 6SL3300-1AF32-5AA0 50 kW 6SL3000-1BF32-5AA0
6SL3310-1GF34-1AAx 250 kW 6SL3300-1AF32-5BA0 50 kW 6SL3000-1BF32-5AA0
6SL3310-1GF34-7AAx 315 kW 6SL3300-1AF32-5BA0 50 kW 6SL3000-1BF32-5AA0
6SL3310-1GF35-8AAx 400 kW 6SL3300-1AF32-5BA0 50 kW 6SL3000-1BF32-5AA0
6SL3310-1GF37-4AAx 450 kW 6SL3300-1AF32-5BA0 50 kW 6SL3000-1BF32-5AA0
6SL3310-1GF38-1AAx 560 kW 6SL3300-1AF32-5BA0 50 kW 6SL3000-1BF32-5AA0
Line voltage 660 – 690 V 3 AC
6SL3310-1GH28-5AAx 75 kW 6SL3300-1AH31-3AA0 25 kW 6SL3000-1BH31-3AA0
6SL3310-1GH31-0AAx 90 kW 6SL3300-1AH31-3AA0 25 kW 6SL3000-1BH31-3AA0
6SL3310-1GH31-2AAx 110 kW 6SL3300-1AH31-3AA0 25 kW 6SL3000-1BH31-3AA0
6SL3310-1GH31-5AAx 132 kW 6SL3300-1AH31-3AA0 25 kW 6SL3000-1BH31-3AA0
6SL3310-1GH31-8AAx 160 kW 6SL3300-1AH32-5AA0 50 kW 6SL3000-1BH32-5AA0
6SL3310-1GH32-2AAx 200 kW 6SL3300-1AH32-5AA0 50 kW 6SL3000-1BH32-5AA0
6SL3310-1GH32-6AAx 250 kW 6SL3300-1AH32-5AA0 50 kW 6SL3000-1BH32-5AA0
6SL3310-1GH33-3AAx 315 kW 6SL3300-1AH32-5AA0 50 kW 6SL3000-1BH32-5AA0
6SL3310-1GH34-1AAx 400 kW 6SL3300-1AH32-5BA0 50 kW 6SL3000-1BH32-5AA0
6SL3310-1GH34-7AAx 450 kW 6SL3300-1AH32-5BA0 50 kW 6SL3000-1BH32-5AA0
6SL3310-1GH35-8AAx 560 kW 6SL3300-1AH32-5BA0 50 kW 6SL3000-1BH32-5AA0
6SL3310-1GH37-4AAx 710 kW 6SL3300-1AH32-5BA0 50 kW 6SL3000-1BH32-5AA0
6SL3310-1GH38-1AAx 800 kW 6SL3300-1AH32-5BA0 50 kW 6SL3000-1BH32-5AA0

General
2.2 Braking resistor
Braking Module / braking resistor
Operating Instructions, 03/2012, A5E00331454A 11
2.2 Braking resistor
Description
In converters with no regenerative feedback capability, the energy that occurs in the drive
train under regenerative conditions is fed back to the DC link where it is reduced via braking
resistors.
The braking resistor is connected to the Braking Module. The distance between the Braking
Module and braking resistor must not exceed 100 m. This enables the resulting heat loss to
be dissipated outside the switchgear room.
Resistors with rated powers of 25 kW and 50 kW are available.
To boost performance, Braking Modules and braking resistors can be connected in parallel.
In this case, the Braking Modules are installed in the discharged air ducts of the Power
Module. Depending on the size of the Power Module, overall up to 3 slots are available:
● Frame size FX: 1
● Frame size GX: 1
● Frame size HX: 2
● Frame size JX: 3
Since the braking resistors can be used in converters with a wide voltage range, the voltage
can be adjusted (for example, to reduce the voltage stress on the motor and converter) by
setting the response thresholds on the Braking Module.
A thermostat monitors the braking resistor for excessively high temperatures and issues a
signal on a floating contact if the limit value is exceeded.

General
2.2 Braking resistor
Braking Module / braking resistor
12 Operating Instructions, 03/2012, A5E00331454A

Braking Module / braking resistor
Operating Instructions, 03/2012, A5E00331454A 13
Mechanical installation 3
3.1 General
WARNING
To ensure that the devices operate safely and reliably, they must be properly installed and
commissioned by qualified personnel, taking into account the warnings provided in these
operating instructions.
In particular, the general and national installation and safety guidelines for high-voltage
installations (e.g. VDE – the Union of German Technical Engineers) as well as the
guidelines relating to the proper use of tools and personal protective equipment must be
observed.
Non-observance can result in death, severe personal injury or substantial material damage.
Tightening torques for screw connections
The following tightening torques apply when tightening connections of operating current-
conducting parts (DC link/motor connections, general busbars), non-operating current-
conducting parts (ground connections, ground terminal connections), and general steel
threaded connections.
Table 3- 1 Tightening torques for screw connections
Thread Ground connections, protective
conductor connections, steel
threaded connections
(fault current-conducting)
Plastic, busbars (operating current-
conducting)
M3 1.3 Nm 0.8 Nm
M4 3 Nm 1.8 Nm
M5 6 Nm 3 Nm
M6 10 Nm 6 Nm
M8 25 Nm 13 Nm
M10 50 Nm 25 Nm
M12 88 Nm 50 Nm
M16 215 Nm 115 Nm
CAUTION
The threaded connections for the protective covers made of Makrolon may only tightened
with 2.5 Nm.

Mechanical installation
3.2 Braking Modules: overview
Braking Module / braking resistor
14 Operating Instructions, 03/2012, A5E00331454A
3.2 Braking Modules: overview
Braking Module for frame size FX
7KUHVKROGVZLWFK
$GDSWHUEDU
5HWDLQLQJVFUHZV
'&3$
'&1$
5
5
;
6 

Figure 3-1 Braking Module for Power Module, frame size FX
Note
With this Braking Module, the R1 and DCPA interfaces use the same connection.

Mechanical installation
3.2 Braking Modules: overview
Braking Module / braking resistor
Operating Instructions, 03/2012, A5E00331454A 15
Braking Module for frame size GX
7KUHVKROGVZLWFK
5HWDLQLQJVFUHZV
'&3$
'&1$
5
5
;


6
Figure 3-2 Braking Module for Power Module, (frame size GX)
Note
With this Braking Module, the R1 and DCPA interfaces use the same connection.

Mechanical installation
3.2 Braking Modules: overview
Braking Module / braking resistor
16 Operating Instructions, 03/2012, A5E00331454A
Braking Module for frame size HX/JX
7KUHVKROGVZLWFK
5HWDLQLQJVFUHZV
'&3$
'&1$
5

5
;
6
Figure 3-3 Braking Module for Power Module, frame size HX/JX

Mechanical installation
3.3 Installing the Braking Module
Braking Module / braking resistor
Operating Instructions, 03/2012, A5E00331454A 17
3.3 Installing the Braking Module
3.3.1 Installing the Braking Module in a Power Module, frame size FX
Figure 3-4 Installing the Braking Module in a Power Module, frame size FX – steps 1 - 3

Mechanical installation
3.3 Installing the Braking Module
Braking Module / braking resistor
18 Operating Instructions, 03/2012, A5E00331454A
Figure 3-5 Installing the Braking Module in a Power Module, frame size FX – steps 4 - 7
Installing the Braking Module
The steps for the installation procedure are numbered in accordance with the figures in the
diagrams.
1. Unscrew the 2 M6 screws from the front cover and lift off the cover.
2. Unscrew the 2 screws from the upper cover plate.
Unscrew the 1 x M6 nut on the left-hand side and remove the front cover.
3. Unscrew the 4 screws from the upper cover plate.
Unscrew the 3 screws from the rear cut-out sections and remove the rear cover.
4. Unscrew the 3 screws for the blanking plate and remove the plate.