Siemens SINAMICS G120 Assembly instructions

Power Module PM260
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SINAMICS
SINAMICS G120
Power Module PM260
Hardware Installation Manual
Edition 08/2013
08/2013
A5E01171966B AD
Introduction
1
Safety notes
2
Description
3
Installing/Mounting
4
Technical specifications
5
Dimensional drawings
6
Spare parts/Accessories
7
Appendix
A
List of abbreviations
B

Siemens AG
Industry Sector
Postfach 48 48
90026 NÜRNBERG
GERMANY
A5E01171966B AD
Ⓟ
08/2013 Technical data subject to change
Copyright © Siemens AG 2013 - 2015.
All
rights reserved
Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
indicates that minor personal injury can result if proper precautions are not taken.
NOTICE
indicates that property damage can result if proper precautions are not taken.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
Qualified Personnel
The product/system described in this documentation may be operated only by
personnel qualified
for the specific
task in accordance with the relevant documentation, in particular its warning notices and safety instructions.
Qualified personnel are those who, based on their training and experience, are capable of identifying risks and
avoiding potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended
or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be complied with. The information in the relevant documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication
may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.

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Table of contents
1 Introduction............................................................................................................................................. 7
2 Safety notes............................................................................................................................................ 9
3 Description............................................................................................................................................ 17
3.1 Power module PM260..................................................................................................................18
3.2 Block diagram ..............................................................................................................................19
4 Installing/Mounting ................................................................................................................................ 21
4.1 Mechanical Installation.................................................................................................................21
4.2 Electrical Installation ....................................................................................................................24
4.2.1 Power and motor connections .....................................................................................................29
4.2.2 Motor circuit..................................................................................................................................33
5 Technical specifications ........................................................................................................................ 35
6 Dimensional drawings ........................................................................................................................... 41
7 Spare parts/Accessories ....................................................................................................................... 43
A Appendix............................................................................................................................................... 47
A.1 Electromagnetic Compatibility......................................................................................................47
A.2 Definition of the EMC Environment and Categories ....................................................................47
A.3 Standards.....................................................................................................................................49
B List of abbreviations .............................................................................................................................. 51
Index..................................................................................................................................................... 53

Table of contents
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Introduction
1
Available technical documentation
Comprehensive information and support tools are available from the Service and Support
internet site
●http://support.automation.siemens.com
You find there the following types of documentation:
●Getting Started
●Operating Instructions
●Hardware Installation Manual
●Function Manual
●Parameter Manual
●Product Information
Further internet addresses
You can download the respective documents for your inverter under the following links:
●SINAMICS G110
http://www.siemens.com/sinamics-g110
●SINAMICS G120
http://www.siemens.com/sinamics-g120
●SINAMICS G120D
http://www.siemens.com/sinamics-g120d
●SIMATIC ET 200S FC
http://www.siemens.com/et200s-fc
●SIMATIC ET 200pro FC
http://www.siemens.com/et200pro-fc
Application examples
You find various application examples to the inverters under the following link:
●http://support.automation.siemens.com/WW/view/en/20208582/136000

Introduction
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Safety notes
2
Safety Instructions
The following Warnings, Cautions and Notes are provided for your safety and as a means of
preventing damage to the product or components in the connected machines. This section
lists Warnings, Cautions and Notes, which apply generally when handling the inverter,
classified as General, Transport and Storage, Commissioning, Operation, Repair and
Dismantling and Disposal.
Specific Warnings, Cautions and Notes that apply to particular activities are listed at the
beginning of the relevant sections in this manual and are repeated or supplemented at
critical points throughout these sections.
Please read the information carefully, since it is provided for your personal safety and will
also help prolong the service life of your inverter and the equipment to which it is connected.
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).
General
WARNING
This equipment controls potentially dangerous rotating mechanical parts.
Protection in case of direct contact by means of voltages < 60V (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 are to be taken, e.g., protective insulation.
The converter must always be properly grounded. Since the residual current for this product
is greater than 3.5mA AC, a fixed ground connection is required, and the minimum size of
the protective conductor must comply with local safety regulations for equipment with a high
leakage current.
Install the converter on a metal mounting plate in a control cabinet. The mounting plate
must not must be painted and must have 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 equal to 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).

Safety notes
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CAUTION
Static discharges on surfaces or interfaces (e.g. terminal or connector pins) can cause
malfunctions or defects. ESD protective measures should therefore be observed when
working with converters or converter components.
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.
Commissioning
WARNING
Working on the equipment by unqualified personnel or failure to comply with warnings can
result in severe personal injury or serious damage to material. Only suitably qualified
personnel trained in the setup, installation, commissioning and operation of the product
should carry out work on the equipment.
CAUTION
Cable connection
The control cables must be laid separately from the power cables. Carry out the
connections as shown in the installation section in this manual, to prevent inductive and
capacitive interference from affecting the correct function of the system.
Mechanical Installation
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).

Safety notes
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WARNING
Power and motor connections
The inverter must be grounded from the supply side and the motor side. If it is not grounded
correctly, extremely dangerous conditions may arise which could prove potentially fatal.
Isolate the mains electrical supply before making or changing connections to the unit.
Ensure that the appropriate circuit-breakers/fuses with the specified current rating are
connected between the power supply and the inverter.
The terminals of the Inverter can carry dangerous voltages even if the inverter is
inoperative. Wait at least 5 minutes to allow the unit to discharge after switching off the line
supply before carrying out any installation work.
When connecting the line supply to the inverter, make sure that the terminal case of the
motor is closed.
When changing from the ON to OFF-state of an operation if an LED or other similar display
is not lit or active; this does not indicate that the unit is switched-off or powered-down.
Ensure that the inverter is configured for the correct supply voltage – it must not be
connected to a higher voltage supply.
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.

Safety notes
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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.
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.
High temperature
CAUTION
The temperature of the surface of the power module and of the operator panel can be
higher than 60 °C during operation and after power off.
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.

Safety notes
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Dismantling and disposal
NOTICE
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 of power drive systems
The control and drive components of a drive system 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.
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 instructions on the components and in the
associated technical user documentation.
When assessing the machine's risk in accordance with the respective local regulations (e.g.,
EC Machinery Directive), the machine manufacturer must take into account the following
residual risks emanating from the control and drive components of a drive system:

Safety notes
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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 outside 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. In the event of a fault, exceptionally high temperatures, including an open fire, as well as
emissions of light, noise, particles, gases, etc. can occur inside and outside the inverter,
e.g.:
–Component malfunctions
–Software errors
–Operating and/or ambient conditions outside of the specification
–External influences / damage
Inverters of the Open Type / IP20 degree of protection must be installed in a metal control
cabinet (or protected by another equivalent measure) such that the contact with fire inside
and outside the inverter is not possible.
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 outside 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.
Note
The components must be protected against conductive contamination (e.g. by installing them
in a control cabinet with degree of protection IP54 according to IEC 60529 or NEMA 12).
Assuming that conductive contamination at the installation site can definitely be excluded, a
lower de
gree of cabinet protection may be permitted.

Safety notes
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For more information about residual risks of the components in a drive system, see the
relevant sections in the technical user documentation.

Safety notes
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Description
3
The SINAMICS G120 range
The SINAMICS G120 inverter has been designed for the accurate and efficient control of the
speed and torque for three-phase motors. The SINAMICS G120 system comprises two basic
modules, the Control Unit (CU) and the Power Module (PM).
The Control Units are divided into the following:
●CU without fail-safe functions
–CU230P-2 HVAC for pump and fan applications with Modbus RTU interface
–CU230P-2 CAN for pump and fan applications with CANopen interface
–CU230P-2 DP for pump and fan applications with PROFIBUS DP interface
–CU240E economic version of the CU240 Control Units (e.g. less terminals, no
encoder interface)
–CU240S standard version of the CU240 Control Units
–CU240S DP like CU240S plus PROFIBUS DP interface (PROFIdrive Profile V4.1)
–CU240S PN like CU240S plus PROFINET interface (PROFIdrive Profile V4.1)
●CU with fail-safe functions
–CU240S DP-F like CU240S DP plus integrated fail-safe functions
–CU240S PN-F like CU240S PN plus integrated fail-safe functions
The Power Modules differ concerning the supply voltage and the way of realizing the motor
braking function:
●PM240 Power Module with resistor braking and dc braking functions, supply voltage
3 AC 400 V
●PM250 Power Module with regenerative braking function, supply voltage 3 AC 400 V
●PM260 Power Module with regenerative braking function, supply voltage 3 AC 690 V
Control Units and Power Modules are allowed to be combined in any possible configuration.
Exceptions:
The CU230P-2 with firmware V4.2 can not be combined with PM240 FSGX or PM260.
These combinations will be allowed with firmware V4.3.
See the respective manual for specific functions and features.

Description
3.1 Power module PM260
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3.1
Power module PM260
Overview
The power modules contain an integrated sine wave output filter for sinusoidal output
voltage. They are available with protection level IP20 according to EN 60529, with or without
integrated Class A filter in the following frame sizes and power ranges:
●Frame size D, 7,5 kW … 15 kW
●Frame size F, 22 kW … 37 kW
The power modules have regenerative capability, where the regeneration limit is the
maximum nominal power (high overload) of the power module.
The PM260 power modules can be used together with G120 standard control units or with
G120 fail-safe control units.
CAUTION
The PM260 power modules can be used for three phase asynchronous motors, syncronous
motors are not allowed.

Description
3.2 Block diagram
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3.2
Block diagram
Block diagram
Figure 3-1 Power Module PM260

Description
3.2 Block diagram
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