Siemens SINAMICS G120 Assembly instructions

s
SINAMICS
G120
G120
Power Module
PM240
Hardware Installation Manual · Edition 04/2006

Introduction
1
Safety notes
2
Description
3
Installing/Mounting
4
Operation (hardware)
5
Technical data
6
Dimension drawings
7
Spare parts/Accessories
8
Appendix
A
List of abbreviations
B
SINAMICS
SINAMICS G120
Power Modules PM240
Hardware Installation Manual
2006-04-04
A5E00807525B AA
Edition 04/2006

Safety Guidelines
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 corresponding 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 device/system may only be set up and used in conjunction with this documentation. Commissioning and
operation of a device/system may only be performed by qualified personnel. Within the context of the safety notes
in this documentation qualified persons are defined as persons who are authorized to commission, ground and
label devices, systems and circuits in accordance with established safety practices and standards.
Prescribed Usage
Note the following:
Warning
This device may only be used for the applications described in the catalog or the technical description and only in
connection with devices or components from other manufacturers which have been approved or recommended by
Siemens. Correct, reliable operation of the product requires proper transport, storage, positioning and assembly
as well as careful operation and maintenance.
Trademarks
All names identified by ® are registered trademarks of the 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
Automation and Drives
Postfach 48 48
90437 NÜRNBERG
GERMANY
Order No.: A5E00807525B AA
Edition 04/2006
Copyright © Siemens AG 2006.
Technical data subject to change

Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA iii
Table of contents
1 Introduction............................................................................................................................................. 1-1
1.1 Documents for the SINAMICS G120 ......................................................................................... 1-1
2 Safety notes............................................................................................................................................ 2-1
3 Description.............................................................................................................................................. 3-1
3.1 SINAMICS G120 Power Modules - PM240 ............................................................................... 3-2
3.2 Power Range of SINAMICS G120 power modules PM240....................................................... 3-2
3.3 Block diagram PM240................................................................................................................ 3-3
3.4 Accessories for the SINAMICS G120 ........................................................................................ 3-4
4 Installing/Mounting.................................................................................................................................. 4-1
4.1 Mechanical Installation............................................................................................................... 4-1
4.2 Electrical Installation .................................................................................................................. 4-5
5 Operation (hardware).............................................................................................................................. 5-1
5.1 Installation conditions................................................................................................................. 5-1
6 Technical data ........................................................................................................................................ 6-1
6.1 Mechanical Data ........................................................................................................................ 6-1
6.2 Electrical Data............................................................................................................................ 6-5
7 Dimension drawings ............................................................................................................................... 7-1
7.1 Dimensions of the PM240.......................................................................................................... 7-1
8 Spare parts/Accessories......................................................................................................................... 8-1
8.1 Replacing a Cooling Fan............................................................................................................ 8-1
8.2 Power Module accessories........................................................................................................ 8-3
8.3 Brake Control Relays ................................................................................................................. 8-7
A Appendix.................................................................................................................................................A-1
A.1 Electromagnetic Compatibility....................................................................................................A-1
A.2 Definition of the EMC Environment and Categories .................................................................. A-2
A.3 EMC Overall Performance.........................................................................................................A-4
A.4 Standards...................................................................................................................................A-6
B List of abbreviations................................................................................................................................B-1
Index................................................................................................................................................ Index-1

Table of contents
Power Modules PM240
iv Hardware Installation Manual, 2006-04-04, A5E00807525B AA
Tables
Table 3-1 SINAMICS G120 power modules PM240.................................................................................. 3-2
Table 4-1 Distances to other equipment .................................................................................................... 4-1
Table 4-2 Dimensions and tightening torques of SINAMICS G120 power modules.................................. 4-3
Table 4-3 Example 1LA7060-4AB10........................................................................................................ 4-16
Table 6-1 Distances to other equipment .................................................................................................... 6-1
Table 6-2 Dimensions and tightening torques of SINAMICS G120 power modules.................................. 6-4
Table 6-3 Air cooling requirements ............................................................................................................ 6-6
Table 6-4 Current reduction depending on pulse frequency...................................................................... 6-6
Table 6-5 Data for braking resistors ........................................................................................................... 6-7
Table 6-6 Rated Output, Input and Fuses..................................................................................................6-8
Table 6-7 Rated Output, Input and Fuses..................................................................................................6-9
Table 6-8 Input, Output Cable and Weight............................................................................................... 6-10
Table 6-9 Input, Output Cable and Weight............................................................................................... 6-11
Table 6-10 Performance ratings................................................................................................................. 6-12
Table 6-11 Power terminals - tightening torques ....................................................................................... 6-13
Table 7-1 Additional dimensions ................................................................................................................ 7-1
Table 8-1 DIN rail pitch............................................................................................................................... 8-3
Table 8-2 DIN rail mounting kit ordering information.................................................................................. 8-3
Table 8-3 NEMA 1 kit ordering information ................................................................................................8-4
Table 8-4 Screen termination kit ordering information ............................................................................... 8-4
Table 8-5 Brake module ordering information............................................................................................ 8-5
Table 8-6 Choke and filter ordering information......................................................................................... 8-5
Table 8-7 Braking resistor ordering information ......................................................................................... 8-6
Table A-1 Compliance Table ......................................................................................................................A-3
Table A-2 Conducted & Radiated Emissions .............................................................................................A-4
Table A-3 Harmonic Currents .....................................................................................................................A-4
Table A-4 EMC Immunity............................................................................................................................A-5
Table B-1 Abbreviations used with the SINAMICS G120 Products ...........................................................B-1

Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA 1-1
Introduction 1
1.1 Documents for the SINAMICS G120
Available documentation
The following documents are available for the SINAMICS G120 inverters:
•Brochure
•Catalog
•Getting started Guide
•Operating Instructions
•Hardware Installation Manual
•Compact Operating Instructions (for the Control Units)
•Parameter List.
The documents can be downloaded from the Internet via the following link:
http://www.siemens.de/sinamics-g120
Description of the documents
Brochure
The brochure is advertising literature designed to introduce the product to the marketplace. It
contains a basic outline of the product with a brief overview of the technical capabilities of
the product.
Catalog
The catalog presents information that allows the customer to select an appropriate inverter
including all available options. It contains detailed technical specifications, ordering and
pricing information to allow the customer to order the appropriate items for their application
or plant.
Getting started Guide
The Getting started Guide presents warnings, dimension drawings and a brief set up
information for the customer.

Introduction
1.1 Documents for the SINAMICS G120
Power Modules PM240
1-2 Hardware Installation Manual, 2006-04-04, A5E00807525B AA
Operating Instructions
The Operating Instructions gives information for the Control Unit regarding the features of
the product. It gives detailed information on commissioning, control modes, system
parameters, troubleshooting, technical specifications and the available options from the
product.
Hardware Installation Manual
The Hardware Installation Manual gives information for the Power Modules regarding the
features of the product. It gives detailed information on installation, technical specifications,
dimension drawings and the available options from the product.
Compact Operating Instructions
The Compact Operating Instructions gives a brief description of the installation,
commissioning and control modes as well as an overview of troubleshooting, technical
specifications and the available options from the product.
Parameter List
The Parameter List contains a detailed description of all the parameters that can be modified
and adapted for specific applications. The Parameter List also contains a series of function
diagrams to diagramatically portray the nature and interoperability of the system parameters.

Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA 2-1
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 SINAMICS
G120 product, 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 SINAMICS G120 product and the equipment to
which it is connected.
General
Caution
Children and the general public must be prevented from accessing or approaching the
equipment!
This equipment may only be used for the purpose specified by the manufacturer.
Unauthorized modifications and the use of spare parts and accessories that are not sold or
recommended by the manufacturer of the equipment can cause fires, electric shocks and
injuries.
Notice
Keep these operating instructions within easy reach of the equipment and make them
available to all users.
Whenever measuring or testing has to be performed on live equipment, the regulations of
Safety Code BGV A2 must be observed, in particular § 8 "Permissible Deviations when
Working on Live Parts". Suitable electronic tools should be used.
Before installing and commissioning, please read these safety instructions and warnings
carefully and all the warning labels attached to the equipment. Make sure that the warning
labels are kept in a legible condition and replace missing or damaged labels.

Safety notes
Power Modules PM240
2-2 Hardware Installation Manual, 2006-04-04, A5E00807525B AA
Risk of electric shock
Warning
This equipment contains dangerous voltages and controls potentially dangerous rotating
mechanical parts. Non-compliance with the Warnings or failure to follow the instructions
contained in this manual can result in loss of life, severe personal injury or serious damage
to property.
Only suitable qualified personnel should work on this equipment, and only after becoming
familiar with all safety notices, installation, operation and maintenance procedures contained
in this manual. The successful and safe operation of this equipment is dependent upon ist
proper handling, installation, operation and maintenance.
Take particular notice of the general and regional installation and safety regulations
regarding work on dangerous voltage installation (e.g. EN 50178) as well as the relevant
regulations regarding the correct use of tools and personal protective equipment (PPE).
Risk of electric shock
The line input, DC and motor terminals can carry dangerous voltages even if the SINAMICS
G120 inverter is inoperative. Wait five minutes to allow the unit to discharge after switching
off the line supply before carrying out any installation work.
The terminals can carry dangerous voltages, even after the inverter has become inoperative.
Depending on the frame size the following terminals are for:
•the power supply L/U1/L1, N/V1/L2 and W1/L3
•the motor , U2, V2, W2
•and DCN, DCP/R1, R2.
HP ratings are based on the Siemens 1LA motors and are given for guidance only. They do
not necessarily comply with UL or NEMA HP ratings.
Transport and storage
Warning
Correct transport, storage as well as careful operation and maintenance are essential for the
proper and safe operation of the equipment.
Caution
Protect the equipment against physical shocks and vibration during transport and storage. It
is important that the equipment is protected from water (rainfall) and excessive
temperatures.

Safety notes
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA 2-3
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
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).
The line input, DC and motor terminals can carry dangerous voltages even if the SINAMICS
G120 inverter is inoperative. Wait 5 minutes to allow the unit to discharge after switching off
the line supply before carrying out any installation work.

Safety notes
Power Modules PM240
2-4 Hardware Installation Manual, 2006-04-04, A5E00807525B AA
Electrical installation
Warning
Power and motor connections
The SINAMICS G120 inverter must always be grounded. If the SINAMICS G120 inverter 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 SINAMICS G120 inverter is configured for the correct supply voltage – the
SINAMICS G120 inverter must not be connected to a higher voltage supply.
When synchronous motors are connected or when coupling several motors in parallel, the
SINAMICS G120 inverter must be operated with V/f control characteristics (P1300 = 0, 2 or
3).
Note
TT-/IT power systems can only be used with unfiltered drives.
Caution
Cables
The control cables must be laid separately from the power cables. The connection must be
carried out as shown in the installation section in this manual, to prevent inductive and
capacitive interference from affecting the correct function of the system.

Safety notes
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA 2-5
Operation
Warning
The SINAMICS G120 inverters operate at high voltages.
When operating electrical devices, it is impossible to avoid applying hazardous voltages to
certain parts of the equipment.
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.
Certain parameter settings may cause the SINAMICS G120 inverter to restart automatically
after an input power failure, for example, the automatic restart function.
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.).
Motor parameters must be accurately configured for motor overload protection to operate
correctly.
This equipment is capable of providing internal motor overload protection according to
UL508C. Refer to P0610 and P0335, i2t is ON by default.
This equipment is suitable for use in a circuit capable of delivering not more than 10,000
symmetrical amperes (rms), for a maximum voltage of 460 V when protected by an H, J or K
type fuse, a circuit breaker or self-protected combination motor controller.
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.
Disconnect the power supply before opening the equipment for access.

Safety notes
Power Modules PM240
2-6 Hardware Installation Manual, 2006-04-04, A5E00807525B AA
Dismantling and disposal
Caution
The SINAMICS G120s packaging 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.

Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA 3-1
Description 3
Overview
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).
Control Units
•CU240S
Control Unit for operation via terminals
•CU240S DP
Control Unit for operation via terminals or PROFIBUS DP Communication
•CU240S DP-F
Control Unit with fail-safe functions for operation via terminals or PROFIBUS DP
Communication (PROFIsafe).
Power Modules
•PM240 400 V, IP20
–Frame sizes A unfiltered
–Frame sizes B … F unfiltered or with filter Class A.
PM240 power modules can be used for control units with and without fail-safe funtions.

Description
3.1 SINAMICS G120 Power Modules - PM240
Power Modules PM240
3-2 Hardware Installation Manual, 2006-04-04, A5E00807525B AA
3.1 SINAMICS G120 Power Modules - PM240
Overview
There are the following types of SINAMICS G120 power modules for different applications.
•PM240 power modules with braking capability (resistive braking)
–380 V … 400 V, IP20, Frame sizes A … C unfiltered, 0,37 kW … 11 kW
–380 V … 400 V, IP20, Frame sizes D … F unfiltered, 15 kW … 75 kW
–380 V … 400 V, IP20, Frame sizes B … F unfiltered or filter Class A, 2,2 kW … 11 kW
–380 V … 400 V, IP20, Frame sizes D … F unfiltered or filter Class A, 15 kW … 75 kW.
3.2 Power Range of SINAMICS G120 power modules PM240
Power range of SINAMICS G120 power modules PM240
Table 3-1 SINAMICS G120 power modules PM240
Power Rating Power Rating Voltage Filtered Unfiltered
Power Module
kW Hp V
PM240 FSA 0.37 … 1.5 0.5 … 2.0 380 … 400 -- ✓
PM240 FSB 2.2 … 4.0 3.0 … 5.0 380 … 400 ✓ ✓
PM240 FSC 5.5 … 11.0 7.5 … 15.0 380 … 400 ✓ ✓
PM240 FSD 15.0 … 22.0 20.0 … 30.0 380 … 400 ✓ ✓
PM240 FSE 30.0 … 37.0 40.0 … 50.0 380 … 400 ✓ ✓
PM240 FSF 45.0 … 75.0 60.0 … 100.0 380 … 400 ✓ ✓

Description
3.3 Block diagram PM240
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA 3-3
3.3 Block diagram PM240
Block diagram PM240
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Description
3.4 Accessories for the SINAMICS G120
Power Modules PM240
3-4 Hardware Installation Manual, 2006-04-04, A5E00807525B AA
3.4 Accessories for the SINAMICS G120
Overview
The following options are available for the SINAMICS G120 Inverters:
Control Unit accessories
•OP (Operator Panel)
•PC connection kit
•MMC (Multi Media Card)
•CU screening Kit
Power Module accessories
•DIN rail mounting kit
•NEMA 1 kit
•Screen termination kit
•Brake and Safe brake modules
•Chokes
•Filters
•Braking resistor.
Power Module spare parts
•Fan.
A description of the individual options, there purposes and ordering information is given in
the SINAMICS G120 catalog.

Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA 4-1
Installing/Mounting 4
Overwiew
This section gives an overview about the installation of the SINAMISCS G120 Power
Modules. For technical details please refer to "Technical Data".
4.1 Mechanical Installation
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).
The line input, DC and motor terminals can carry dangerous voltages even if the SINAMICS
G120 inverter is inoperative. Wait 5 minutes to allow the unit to discharge after switching off
the line supply before carrying out any installation work.
Distances to other equipment
When mounting the SINAMICS G120 Power Modules one above the other or side by side,
the specified environmental conditions must not be exceeded. Independent of this, these
minimum distances of the SINAMICS G120 Power Modules must be observed:
Table 4-1 Distances to other equipment
A B C D E F
Frame
Size mm inch mm inch mm inch mm inch mm inch mm inch
Side
by
Side
30 1.18 40 1.57 50 1.96 0 0 0 0 0 0
Above
and
Below
100 3.93 100 3.93 125 4.92 300 11.81 300 11.81 350 13.77

Installing/Mounting
4.1 Mechanical Installation
Power Modules PM240
4-2 Hardware Installation Manual, 2006-04-04, A5E00807525B AA
Drill patterns for SINAMICS G120 power modules FSA to FSF
To allow the preliminary installation work to be undertaken, drill patterns for all the frame
sizes of the SINAMICS G120 power modules are shown below.
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Figure 4-1 Drill patterns for SINAMICS G120 power modules FSA to FSF
Dimensions and tightening torques of SINAMICS G120 power modules
The dimensions and tightening torques for securing the inverter are given in the table below.