Siemens SINAMICS S120 Technical Document

Equipment Manual 04/2004 Edition
SINAMICS S120
Booksize Power Sections

Preface
System Overview
1
Line Connection Booksize
2
Line Modules Booksize
3
Motor Modules Booksize
4
DC Link Components
Booksize
5
Cabinet Configuration and
EMC Booksize
6
Service and Support
Booksize
7
Appendix A
A
Appendix B
B
SINAMICS
SINAMICS S120
Booksize Power Sections
Equipment Manual
(GH2), 04.2004 Edition

SINAMICS® Documentation
Printing history
Brief details of this edition and previous editions are listed below.
The status of each edition is shown by the code in the "Remarks" column.
Status code in the "Remarks" column:
A New documentation
B Unrevised reprint with new order no.
C Revised edition with new status
If factual changes have been made on the page in relation to the same software version, this is indicated by a new edition
coding in the header on that page.
Edition Order No. Remarks
04.04 6SL3097-2AC00-0BP0 A
Trademarks
SIMOVERT®, SIMATIC®, SIMATIC HMI®, SIMATIC NET®, SIMOTION®, SINUMERIK® and SINAMICS® are trademarks of
Siemens. Other product names used in this documentation may be trademarks which, if used by third parties, could infringe the
rights of their owners.
Further information is available on the Internet under:
http://www.siemens.com/motioncontrol
This publication was produced with SIPS+
The reproduction, transmission or use of this document or its contents is not
permitted without express written authority. Offenders will be liable for
damages. All rights, including those created by patent grant or registration of a
utility model or design, are reserved.
© Siemens AG, 2004. All rights reserved
We have checked that the contents of this document correspond to the hardware
and software described. Nonetheless, differences might exist and therefore we
cannot guarantee that they are completely identical. The information contained in
this document is, however, reviewed regularly and any necessary changes will
be included in the next edition. We welcome suggestions for improvement.
Subject to changes without prior notice
Order No. 6SL3097-2AC00-0BP0
Printed in Germany
Siemens Aktiengesellschaft

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Preface
Preface
Information on the SINAMICS S documentation
The SINAMICS S documentation is divided into the following areas:
• General documentation/catalogs
• Manufacturer/service documentation
• Electronic documentation
This documentation is an integral part of the manufacturer/service documentation developed
for SINAMICS. All documents can be obtained separately.
You can obtain detailed information about the documents named in the documentation
overview and other documents available for SINAMICS from your local Siemens office.
For the sake of simplicity, this documentation does not contain all detailed information about
all types of the product and cannot cover every conceivable case of installation, operation, or
maintenance.
The contents of this documentation are not part of an earlier or existing agreement, a
promise, or a legal agreement, nor do they change this. All obligations entered into by
Siemens result from the respective contract of sale that contains the complete and sole valid
warranty arrangements. These contractual warranty provisions are neither extended nor
curbed as a result of the statements made in this documentation.
Audience
This documentation is aimed at machine and plant builders, commissioning engineers, and
service personnel who use SINAMICS.
Objective
This manual describes the hardware components of the SINAMICS S system. It provides
information about installation, electrical connection, and cabinet design.

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Danger and warning notices – symbol explanations
The following danger and warning notices are used in this document:
Danger
Indicates an imminently hazardous situation which, if not avoided, will result in death, serious
injury, or substantial damage to property.
Warning
Indicates an potentially hazardous situation which, if not avoided, could result in death, or
serious injury, or substantial property damage.
Caution
Used with the safety alert symbol indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury or property damage.
Caution
Used without safety alert symbol indicates a potentially hazardous situation which, if not
avoided, may result in property damage.
Notice
Used without the safety alert symbol indicates a potential situation which, if not avoided, may
result in an undesirable result or state.
Note
This notice indicates that there are further issues to be taken into consideration.

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Definition: Qualified personnel
With reference to this manual and the warning labels on the product, a "qualified person" is
someone who is familiar with the installation, mounting, startup, and operation of the
equipment and who has certified qualifications for the type of responsibility involved, such
as:
• Training and instruction, i.e. authority to switch on and off, to earth and to label circuits
and equipment according to safety regulations.
• Training and instruction in maintenance and use of adequate safety equipment according
to safety regulations.
• First aid training.
Finding information
To help you find information more easily, the following sections have been included in the
appendix in addition to the table of contents:
1. References
2. Index

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Technical information
Hotline
If you have any further questions, please call our hotline:
A&D Technical Support
Tel.: [phone] - 222
Fax: [phone] - 223
E-mail: [email protected]
Please send any questions about the documentation (suggestions for improvement,
corrections, and so on) to the following fax number or e-mail address:
Fax: [phone] - 2176
Fax form: See feedback page at the end of this publication
Email: [email protected]
Internet address
Up-to-date information about our products can be found on the Internet at the following
address:
http://www.siemens.com/motioncontrol

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ESD notices
Caution
Electrostatic sensitive devices (ESDs) are individual components, integrated circuits, or
boards that may be damaged by either electrostatic fields or electrostatic discharge.
Regulations for handling ESD components:
When handling components, make sure that personnel, workplaces, and packaging are well
earthed!
Personnel in ESD areas with conductive flooring may only handle electronic components if
They are grounded with an ESD wrist band
They are wearing ESD shoes or ESD shoe grounding straps.
Electronic boards should only be touched if absolutely necessary. They must only be
handled on the front panel or, in the case of printed circuit boards, at the edge.
Electronic boards must not come into contact with plastics or items of clothing containing
synthetic fibers.
Boards must only be placed on conductive surfaces (work surfaces with ESD surface,
conductive ESD foam, ESD packing bag, ESD transport container).
Do not place boards near display units, monitors, or television sets (minimum distance from
screen: 10 cm).
Measurements must only be taken on boards when
the measuring instrument is grounded (via protective conductors, for example)
the measuring probe is briefly discharged before measurements are taken with an isolated
measuring device (for example, touching a bare metal housing).

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Safety guidelines
Danger
Commissioning shall not start until you have ensured that the machine in which the
components described here are to be installed complies with Directive 98/37/EC.
SINAMICS S equipment must only be commissioned by suitably qualified personnel.
The personnel must take into account the information provided in the technical customer
documentation for the product, and be familiar with and observe the specified danger and
warning notices.
When electrical equipment and motors are operated, the electrical circuits automatically
conduct a dangerous voltage.
Dangerous mechanical movements may occur in the system during operation.
All work on the electrical system must be performed after the system has been switched off
and disconnected from the power supply.
SINAMICS S equipment with three-phase motors may only be connected to the line system
via residual current devices (RCDs) if compatibility of the SINAMICS equipment with the
RCD has been ensured as specified in EN 50178, Subsection 5.2.11.2.
Warning
Correct and safe operation of SINAMICS S equipment assumes correct transportation,
storage, setup, and installation, as well as careful operation and maintenance.
The details in the catalogs and proposals also apply to the design of special equipment
versions.
In addition to the danger and warning information provided in the technical customer
documentation, the applicable national, local, and system-specific regulations and
requirements must be taken into account.
Only protective extra-low voltages (PELVs) that comply with EN60204-1 must be connected
to all connections and terminals between 0 and 48 V.

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Caution
As part of routine tests, SINAMICS equipment with three-phase motors will undergo a
voltage test in accordance with EN 50178. Before the voltage test is performed on the
electrical equipment of industrial machines to EN 60204-1, Section 19.4, all connectors of
SINAMICS equipment must be disconnected/unplugged to prevent the equipment from
being damaged.
Motors must be connected in accordance with the circuit diagram provided. They must not
be connected directly to the three-phase supply because this will damage them.
Note
When operated in dry operating areas, SINAMICS equipment with three-phase motors
conforms to low-voltage Directive 73/23/EEC.
SINAMICS equipment with three-phase motors conforms to EMC Directive 89/336/EEC in
the configurations specified in the associated EC Certificate of Conformity.
Caution
Operating the equipment in the immediate vicinity (< 1.5 m) of mobile telephones with a
transmitter power of > 1 W may lead to incorrect operation.

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Notes

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Table of Contents
Preface ......................................................................................................................................................iii
1System Overview.................................................................................................................................... 1-1
1.1 Applications................................................................................................................................ 1-1
1.2 Versions ..................................................................................................................................... 1-2
1.3 Platform concept and Totally Integrated Automation................................................................. 1-3
1.4 Introduction ................................................................................................................................ 1-4
1.5 SINAMICS S120 components.................................................................................................... 1-7
1.6 Power sections........................................................................................................................... 1-9
1.7 System data ............................................................................................................................. 1-10
2Line Connection Booksize ...................................................................................................................... 2-1
2.1 Introduction ................................................................................................................................ 2-1
2.2 Line connection variations ......................................................................................................... 2-2
2.2.1 Methods of line connection ........................................................................................................ 2-2
2.2.2 Operation of the line connection components on the supply network ....................................... 2-4
2.2.3 Operation of the line connection components via an autotransformer ...................................... 2-5
2.2.4 Operation of the line connection components via an isolating transformer............................... 2-6
2.2.5 Line connection via a ground-fault circuit interrupter ................................................................. 2-7
2.3 Line filters................................................................................................................................... 2-9
2.3.1 Description ................................................................................................................................. 2-9
2.3.2 Safety information ...................................................................................................................... 2-9
2.3.3 Interface description................................................................................................................. 2-11
2.3.4 Dimension drawing .................................................................................................................. 2-13
2.3.5 Technical specification............................................................................................................. 2-14
2.4 Line reactors ............................................................................................................................ 2-15
2.4.1 Description ............................................................................................................................... 2-15
2.4.2 Safety information .................................................................................................................... 2-15
2.4.3 Interface description................................................................................................................. 2-16
2.4.4 Dimension drawing .................................................................................................................. 2-17
2.4.5 Technical specifications ........................................................................................................... 2-18
3Line Modules Booksize........................................................................................................................... 3-1
3.1 Introduction ................................................................................................................................ 3-1
3.2 Active line modules booksize internal air cooling ...................................................................... 3-3
3.2.1 Description ................................................................................................................................. 3-3
3.2.2 Safety information ...................................................................................................................... 3-4
3.2.3 Interface description................................................................................................................... 3-5
3.2.4 Dimension drawing .................................................................................................................. 3-10
3.2.5 Installation ................................................................................................................................ 3-12
3.2.6 Electrical connection ................................................................................................................ 3-13
3.2.7 Technical specifications ........................................................................................................... 3-14

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3.3 Smart line module booksize internal air cooling....................................................................... 3-17
3.3.1 Description ............................................................................................................................... 3-17
3.3.2 Safety information .................................................................................................................... 3-18
3.3.3 Interface description................................................................................................................. 3-19
3.3.4 Dimension drawing................................................................................................................... 3-23
3.3.5 Electrical connection ................................................................................................................ 3-24
3.3.6 Technical specification ............................................................................................................. 3-25
4Motor Modules Booksize......................................................................................................................... 4-1
4.1 Introduction ................................................................................................................................ 4-1
4.2 Motor modules booksize internal air cooling.............................................................................. 4-2
4.2.1 Description ................................................................................................................................. 4-2
4.2.2 Safety information ...................................................................................................................... 4-3
4.2.3 Interface description................................................................................................................... 4-4
4.2.4 Dimension drawings................................................................................................................. 4-11
4.2.5 Installation ................................................................................................................................ 4-15
4.2.6 Electrical connection ................................................................................................................ 4-16
4.2.7 Technical specifications ........................................................................................................... 4-17
5DC Link Components Booksize .............................................................................................................. 5-1
5.1 Braking module booksize ........................................................................................................... 5-1
5.1.1 Description ................................................................................................................................. 5-1
5.1.2 Safety information ...................................................................................................................... 5-2
5.1.3 Interface descriptions ................................................................................................................. 5-3
5.1.4 Dimension drawing..................................................................................................................... 5-7
5.1.5 Mounting..................................................................................................................................... 5-8
5.1.6 Technical specifications ............................................................................................................. 5-9
5.2 Braking resistors ...................................................................................................................... 5-10
5.3 Capacitor module booksize......................................................................................................5-12
5.3.1 Description ............................................................................................................................... 5-12
5.3.2 Safety information .................................................................................................................... 5-12
5.3.3 Interface description................................................................................................................. 5-13
5.3.4 Dimension drawing................................................................................................................... 5-14
5.3.5 Installation ................................................................................................................................ 5-15
5.3.6 Technical specification ............................................................................................................. 5-16
5.4 Control supply module (available soon)................................................................................... 5-17
5.4.1 Description ............................................................................................................................... 5-17
5.4.2 Safety information .................................................................................................................... 5-18
5.4.3 Interface description................................................................................................................. 5-19
5.4.4 Dimension drawing................................................................................................................... 5-22
5.4.5 Technical specification ............................................................................................................. 5-23
6Cabinet Configuration and EMC Booksize.............................................................................................. 6-1
6.1 Information ................................................................................................................................. 6-1
6.1.1 General....................................................................................................................................... 6-1
6.1.2 Safety information ...................................................................................................................... 6-2
6.1.3 Directives and standards............................................................................................................ 6-3
6.2 Selection of devices required for operation of SINAMICS ......................................................... 6-4
6.2.1 General....................................................................................................................................... 6-4
6.2.2 Information about line isolating devices ..................................................................................... 6-4
6.2.3 Overcurrent protection by line fuse or circuit-breaker................................................................ 6-5
6.2.4 Line contactors........................................................................................................................... 6-6

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6.3 24 V DC supply voltage ............................................................................................................. 6-7
6.3.1 General ...................................................................................................................................... 6-7
6.3.2 Selection of power supply units ................................................................................................. 6-8
6.3.3 Typical 24-V component power consumption............................................................................ 6-9
6.3.4 Overcurrent protection ............................................................................................................. 6-10
6.4 Arrangement of components and devices ............................................................................... 6-13
6.4.1 General .................................................................................................................................... 6-13
6.4.2 Drive line-up............................................................................................................................. 6-13
6.5 Information about electromagnetic compatibility (EMC) and cable laying............................... 6-17
6.5.1 General .................................................................................................................................... 6-17
6.5.2 Cable shielding and laying....................................................................................................... 6-17
6.5.3 Equipotential bonding .............................................................................................................. 6-19
6.6 Connection methods ................................................................................................................ 6-20
6.6.1 Spring-loaded terminals/screw terminals................................................................................. 6-20
6.6.2 Motor connector ....................................................................................................................... 6-22
6.6.3 24-V terminal adapter .............................................................................................................. 6-23
6.7 Information about heat dissipation........................................................................................... 6-24
6.7.1 General .................................................................................................................................... 6-24
6.7.2 Information about ventilation.................................................................................................... 6-28
6.7.3 Power loss of components in rated operation.......................................................................... 6-30
6.7.4 Information about calculating power loss................................................................................. 6-32
7Service and Support Booksize................................................................................................................ 7-1
7.1 Technical support....................................................................................................................... 7-1
7.2 Replacing fans ........................................................................................................................... 7-2
7.3 List of spare parts ...................................................................................................................... 7-4
A Appendix A .............................................................................................................................................A-1
A.1 List of abbreviations ...................................................................................................................A-1
B Appendix B .............................................................................................................................................B-1
B.1 References.................................................................................................................................B-1
Index

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System Overview 1
1.1 Applications
SINAMICS is the new range of drives from Siemens designed for mechanical and plant
engineering applications. SINAMICS offers solutions for all drive tasks:
• Simple pump and fan applications in the process industry
• Complex individual drives in centrifuges, presses, extruders, elevators, as well as
conveyor and transport systems
• Drive line-ups in textile, plastic film, and paper machines, as well as in rolling mill plants
• Highly dynamic servo drives for machine tools, as well as packaging and printing
machines.
Depending on the application, the SINAMICS range offers the ideal version for any drive
task.
Figure 1-1 SINAMICS applications

System Overview
1.2 Versions
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1.2 Versions
SINAMICS offers different versions designed to meet a range of requirements:
• SINAMICS G is designed for standard applications with asynchronous motors. These
applications have less stringent requirements regarding the dynamics and accuracy of
the motor speed.
• SINAMICS S handles complex drive tasks with synchronous/asynchronous motors and
fulfills stringent requirements regarding
– Dynamics and accuracy,
– Integration of extensive technological functions in the drive control system.