Siemens SINAMICS G120P User manual

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SINAMICS
SINAMICS G120P
Braking resistors
Operating Instructions
Control version V4.7
10/2016
A5E32845373B AD
Safety information
1
General
2
Mechanical installation
3
Electrical installation
4
Maintenance and servicing
5
Technical specifications
6

Siemens AG
Division Process Industries and Drives
Postfach 48 48
90026 NÜRNBERG
GERMANY
A5E32845373B AD
Ⓟ
10/2016 Subject to change
Copyright © Siemens AG 2013 - 2016.
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
mai
ntenance 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.

Braking resistors
Operating Instructions, 10/2016, A5E32845373B AD 5
Table of contents
1 Safety information ................................................................................................................................... 7
1.1 Warnings...................................................................................................................................7
2 General................................................................................................................................................... 9
3 Mechanical installation .......................................................................................................................... 13
3.1 General ...................................................................................................................................13
3.2 Installing the braking resistor ..................................................................................................14
4 Electrical installation.............................................................................................................................. 15
4.1 Cable lugs ...............................................................................................................................15
4.2 Connecting the braking resistor ..............................................................................................16
4.3 Parameterizing operation with braking resistor ......................................................................17
5 Maintenance and servicing.................................................................................................................... 19
6 Technical specifications ........................................................................................................................ 21

Table of contents
Braking resistors
6Operating Instructions, 10/2016, A5E32845373B AD

Braking resistors
Operating Instructions, 10/2016, A5E32845373B AD 7
Safety information
1
1.1
Warnings
WARNING
Danger to life if the fundamental safety instructions and remaining risks are not carefully
observed
Non-compliance with the fundamental safety instructions and residual risks stated in
Chapter 1 of the Installation Manual for PM330 Power Modules can result in accidents with
severe injuries or death.
•Adhere to the fundamental safety instructions.
•When assessing the risk, take into account residual risks.
Note
Use of copper cables for a UL-approved system
For a UL
-approved system use 60/75°C copper conductors only.
Preconditions
The persons responsible for the safety of the plant or system must ensure that the following
conditions are met:
●Basic planning work for the system and all work relating to transportation, assembly,
installation, commissioning, maintenance and repairs is carried out by qualified personnel
and checked by responsible, suitably skilled personnel.
●The Operating Instructions 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.
These Operating Instructions are intended for qualified personnel and only contain
information and notes relating to the intended purpose of the machines.
The Operating Instructions and machine documentation are written in different languages as
specified in the delivery contracts.

Safety information
1.1 Warnings
Braking resistors
8Operating Instructions, 10/2016, A5E32845373B AD
Note
Support by SIEMENS service centers
We recommend engaging the support and services of your loc
al Siemens service center for
all planning, installation, commissioning and maintenance work.

Braking resistors
Operating Instructions, 10/2016, A5E32845373B AD 9
General
2
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 ratings of 50 kW are available.
To boost performance, Braking Modules and braking resistors can be connected in parallel.
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.
WARNING
Fire hazard due to overheating when permissible connection cable lengths are exceeded
Excessively long Braking Module connection cables can cause components to overheat
with the associated risk of fire and smoke.
•The lengths of the Braking Module connection cables may not exceed 100 m.
WARNING
Fire hazard due to overheating because of inadequate ventilation clearances
Inadequate ventilation clearances can cause overheating with a risk for personnel through
smoke development and fire. This can also result in increased failures and reduced service
lives of braking resistors.
•It is essential that you maintain a ventilation clearance of 200 mm on all sides of the
component with ventilation grills.

General
Braking resistors
10 Operating Instructions, 10/2016, A5E32845373B AD
WARNING
Risk of fire and damage to equipment due to short-circuit/ground fault
The cables to the braking resistor must be routed so that a ground fault or short circuit can
be ruled out. A ground fault can result in fire with the associated smoke.
•Protect the cables from mechanical damage.
•Comply with local installation regulations that enable this fault to be ruled out.
In addition, apply one of the following measures:
•Use cables with double insulation.
•Maintain adequate clearance, using spacers, for example.
•Route the cables in separate cable ducts or pipes.
WARNING
Risk of fire through power loss of the braking resistor
A braking resistor which is not mounted properly can cause components to overheat with
the associated risk of fire and development of smoke.
•Only mount braking resistors on a baseplate/floor.
•Mount the braking resistors so that they are in the vertical position and freestanding.
Sufficient space must be available for dissipating the energy converted by the braking
resistor.
•Maintain sufficient clearance to objects that can burn.
•Do not place any objects on or above the braking resistor.
CAUTION
Risk of burns due to high surface temperature of the braking resistor
The braking resistor can become very hot. You can get seriously burnt when touching the
surface.
•Mount the braking resistors so that contact is not possible. If this is not possible, attach
a clearly visible and understandable warning notice at hazardous positions.
NOTICE
Material damage due to water penetrating the braking resistor
Water penetration may damage the braking resistor.
•For outdoor installations a hood must be provided to protect it from precipitation in
accordance with degree of protection IP20.

General
Braking resistors
Operating Instructions, 10/2016, A5E32845373B AD 11
Note
Braking resistor / fire alarm sensor interaction
If a braking resistor is placed underneath a fire alarm sensor then the heat produced may
trigger the fire alarm sensor.
Assignment of Braking Module and Power Module
Table 2- 1 Assignment of Braking Module and Power Module
Power Module
Rated power of
the Power
Module
Suitable Braking
Module
Suitable braking
resistor
Rated power of the
braking resistor
Line voltage 380 – 480 V 3 AC
6SL3310-1PE33-0AA0
160 kW
6SL3760-1AE32-6AA0
6SE7032-5FS87-2DC0
50 kW
6SL3310-1PE33-7AA0
200 kW
6SL3760-1AE32-6AA0
6SE7032-5FS87-2DC0
50 kW
6SL3310-1PE34-6AA0
250 kW
6SL3760-1AE32-6AA0
6SE7032-5FS87-2DC0
50 kW
6SL3310-1PE35-8AA0
315 kW
6SL3760-1AE32-6AA0
6SE7032-5FS87-2DC0
50 kW
6SL3310-1PE36-6AA0
355 kW
6SL3760-1AE32-6AA0
6SE7032-5FS87-2DC0
50 kW
6SL3310-1PE37-4AA0
400 kW
6SL3760-1AE32-6AA0
6SE7032-5FS87-2DC0
50 kW
6SL3310-1PE38-4AA0
450 kW
6SL3760-1AE32-6AA0
6SE7032-5FS87-2DC0
50 kW
6SL3310-1PE38-8AA0
500 kW
6SL3760-1AE32-6AA0
6SE7032-5FS87-2DC0
50 kW
6SL3310-1PE41-0AA0
560 kW
6SL3760-1AE32-6AA0
6SE7032-5FS87-2DC0
50 kW

General
Braking resistors
12 Operating Instructions, 10/2016, A5E32845373B AD

Braking resistors
Operating Instructions, 10/2016, A5E32845373B AD 13
Mechanical installation
3
3.1
General
Tightening torques for screw connections
The following tightening torques apply when tightening current-conducting connections
(DC link connections, motor connections, busbars, cable lugs) and other connections
(ground connections, protective ground connections, steel threaded connections/glands).
Table 3- 1 Tightening torques for screw connections
Thread
Ground connections, protective
ground connections, steel threaded
connections/glands
Aluminum threaded connec-
tions/glands, plastic, busbars,
cable lugs
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

Mechanical installation
3.2 Installing the braking resistor
Braking resistors
14 Operating Instructions, 10/2016, A5E32845373B AD
3.2
Installing the braking resistor
The braking resistor should not be installed in the vicinity of the converter. The following
points must be taken into account:
●The braking resistors are only suitable for floor mounting.
●The maximum cable length between the Braking Module and braking resistor is 100 m.
●Sufficient space must be available for dissipating the energy converted by the braking
resistor.
●A sufficient distance from flammable objects must be maintained.
●The braking resistor must be installed as a free-standing unit.
●Objects must not be placed on or anywhere above the braking resistor.
●The braking resistor should not be installed underneath fire detection systems, since
these could be triggered by the resulting heat.
●For outdoor installation, a hood must be provided to protect the braking resistor from
precipitation (in accordance with degree of protection IP20).
Figure 3-1 Dimension drawing for braking resistor (50 kW)

Braking resistors
Operating Instructions, 10/2016, A5E32845373B AD 15
Electrical installation
4
4.1
Cable lugs
Cable lugs
The cable connections on the devices are designed for cable lugs according to DIN 46234 or
DIN 46235.
For connection of alternative cable lugs, the maximum dimensions are listed in the table
below.
These cable lugs are not to exceed these dimensions, as mechanical fastening and
adherence to the voltage distances is not guaranteed otherwise.
Figure 4-1 Dimensions of the cable lugs
Table 4- 1 Dimensions of the cable lugs
Screw / bolts
Connection cross-section
[mm²]
d2
[mm]
b
[mm]
l
[mm]
c1
[mm]
c2
[mm]
M8
70
8.4
24
55
13
10
M10
185
10.5
37
82
15
12
M10
240
13
42
92
16
13
M12
95
13
28
65
16
13
M12
185
13
37
82
16
13
M12
240
13
42
92
16
13
M16
240
17
42
92
19
16

Electrical installation
4.2 Connecting the braking resistor
Braking resistors
16 Operating Instructions, 10/2016, A5E32845373B AD
4.2
Connecting the braking resistor
DANGER
Danger to life through electric shock due to applied voltage and residual charge of the
DC link capacitors on the Braking Module
Contact with live connections on the Braking Module can result in death or serious injury.
•Only connect the Braking Module after the Power Module has been disconnected from
the power supply.
•Only connect the Braking Module after 5 minutes have elapsed. Measure the voltage
before starting work on the DCP and DCN DC link terminals.
WARNING
Risk of fire due to ground fault/short-circuit
Inadequate installation of the cables to the braking resistor can result in a ground
fault/short-circuit and place persons at risk as a result of the associated smoke and fire.
•Use the local installation regulations to avoid this fault.
•Protect the cables against mechanical damage.
•Also implement one of the following measures:
–Use cables with double insulation.
–Maintain adequate clearance, e.g. by using spacers.
–
Lay the cables in separate cable ducts or conduits.
WARNING
Fire hazard due to overheating when permissible connection cable lengths are exceeded
Excessively long Braking Module connection cables can cause components to overheat
with the associated risk of fire and smoke.
•The lengths of the Braking Module connection cables may not exceed 100 m.
Recommended connection cross-section: 35 mm².

Electrical installation
4.3 Parameterizing operation with braking resistor
Braking resistors
Operating Instructions, 10/2016, A5E32845373B AD 17
Thermostatic switch
A thermostatic switch is installed to protect the braking resistor against overload. Its floating
contacts must be integrated in the fault chain on site.
Table 4- 2 Thermostatic switch connection
Terminal
Description of function
Technical data
T1
Thermostatic switch connection
Voltage: 250 V AC
Load current: max. 1 A
T2 Thermostatic switch connection
Max. connectable cross-section: 2.5 mm²
Integration of the thermostatic switch as release for switch-off via OFF2
The thermostatic switch must be connected to a free digital input so that the converter is
safely disconnected from the power supply if the braking resistor overheats. The digital input
of terminal strip X9/4 on the Power Module can be used for this purpose.
4.3
Parameterizing operation with braking resistor
For operation with a braking chopper, the braking power of the braking resistor must be
entered into parameter p0219. As a consequence, the Vdc max controller is automatically
deactivated (p1240 = 0) and the minimum ramp-down time (p1127) and the regenerative
power limit (p1531) are adapted.

Electrical installation
4.3 Parameterizing operation with braking resistor
Braking resistors
18 Operating Instructions, 10/2016, A5E32845373B AD

Braking resistors
Operating Instructions, 10/2016, A5E32845373B AD 19
Maintenance and servicing
5
The braking resistor can neither be maintained nor serviced. In the case of a fault, the
braking resistor must be completely replaced.

Maintenance and servicing
Braking resistors
20 Operating Instructions, 10/2016, A5E32845373B AD