Siemens SINAMICS G120 Assembly instructions

Power Modules PM240
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SINAMICS
SINAMICS G120
Power Modules PM240
Hardware Installation Manual
07/2016
07/2016
A5E36985441C AA
Changes in this manual
1
Fundamental safety
instructions
2
Introduction
3
Installing/mounting
4
Connecting-up
5
Service and maintenance
6
Technical data
7
Spare parts and accessories
8
Appendix
A

Siemens AG
Division Digital Factory
Postfach 48 48
90026 NÜRNBERG
GERMANY
A5E36985441C AA
Ⓟ
06/2016 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
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 Changes in this manual........................................................................................................................... 9
2 Fundamental safety instructions............................................................................................................ 11
2.1 General safety instructions .....................................................................................................11
2.2 Safety instructions for electromagnetic fields (EMF) ..............................................................15
2.3 Handling electrostatic sensitive devices (ESD) ......................................................................15
2.4 Industrial security ....................................................................................................................16
2.5 Residual risks of power drive systems....................................................................................17
3 Introduction........................................................................................................................................... 19
3.1 PM240 Power Modules...........................................................................................................19
3.2 Component specification according to UL ..............................................................................20
4 Installing/mounting ................................................................................................................................ 21
4.1 Installation conditions..............................................................................................................21
4.2 EMC-compliant installation of a plant or machine ..................................................................22
4.2.1 Control cabinet........................................................................................................................22
4.2.2 Cables.....................................................................................................................................25
4.2.3 Electromechanical components..............................................................................................27
4.3 Power losses and air cooling requirements ............................................................................28
4.4 Mounting the Power Modules .................................................................................................30
4.4.1 Dimension drawings and drilling dimensions, FSA ... FSF.....................................................31
4.4.2 Dimensioned drawings and drilling dimensions, FSGX..........................................................33
4.5 Additional components............................................................................................................34
5 Connecting-up ...................................................................................................................................... 35
5.1 Permissible line supplies ........................................................................................................38
5.1.1 TN line system ........................................................................................................................38
5.1.2 TT line system.........................................................................................................................39
5.1.3 IT system ................................................................................................................................39
5.1.4 Protective conductor ...............................................................................................................40
5.2 Connecting the line and motor cable at the inverter ...............................................................42
5.2.1 Connection overview...............................................................................................................42
5.2.2 Connecting inverters in compliance with EMC regulations.....................................................43
5.2.3 Length of motor cable .............................................................................................................43
5.2.4 Inverter terminals ....................................................................................................................45
5.2.5 Establishing connections ........................................................................................................46
5.2.5.1 Connections FSA ... FSC........................................................................................................46
5.2.5.2 Connections FSD … FSF .......................................................................................................46
5.2.5.3 Connections FSGX .................................................................................................................47
5.3 Connecting the motor to the inverter in a star or delta connection.........................................49

Table of contents
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6 Service and maintenance...................................................................................................................... 51
6.1 Maintenance........................................................................................................................... 52
6.2 Commissioning after a long storage time .............................................................................. 53
6.3 Replace the fan ...................................................................................................................... 54
6.4 Replacing the FSGX power block .......................................................................................... 59
7 Technical data ...................................................................................................................................... 61
7.1 Ambient conditions................................................................................................................. 61
7.2 Overload capability of the inverter ......................................................................................... 63
7.3 Cable cross-sections and tightening torques......................................................................... 64
7.4 General data .......................................................................................................................... 65
7.5 Specific technical data ........................................................................................................... 65
7.5.1 Current derating depending on the pulse frequency.............................................................. 70
7.6 Restrictions for special ambient conditions............................................................................ 71
7.7 Electromagnetic compatibility of variable-speed drives......................................................... 73
7.7.1 Inverter applications ............................................................................................................... 75
7.7.1.1 Operation in the second environment.................................................................................... 75
7.7.1.2 Operation in the first environment.......................................................................................... 77
7.7.2 Radio interference suppression filters according to CISPR 11/EN 55011 Class B ............... 78
7.7.3 Harmonic currents.................................................................................................................. 78
7.7.4 EMC limit values in South Korea ........................................................................................... 79
8 Spare parts and accessories................................................................................................................. 81
8.1 Product maintenance ............................................................................................................. 81
8.2 Spare parts............................................................................................................................. 81
8.3 Optional accessories.............................................................................................................. 82
8.3.1 Base components for frame sizes FSA, FSB and FSC ......................................................... 82
8.3.2 Line reactor ............................................................................................................................ 84
8.3.3 Line filter................................................................................................................................. 88
8.3.4 Output reactor ........................................................................................................................ 90
8.3.5 Sine-wave filter....................................................................................................................... 94
8.3.6 Braking Module - only FSGX ................................................................................................. 98
8.3.6.1 Braking Module - settings and connections ........................................................................... 99
8.3.7 Braking resistor .................................................................................................................... 100
8.3.7.1 Connect the temperature contact of the braking resistor..................................................... 104
8.3.8 Connecting a motor holding brake to a Safe Brake Relay................................................... 104
8.3.8.1 Mounting and connecting the brake relay............................................................................ 105
8.3.8.2 Mounting and connecting the Safe Brake Relay.................................................................. 106
8.3.8.3 Technical data of the brake relay?....................................................................................... 106
8.3.8.4 Mounting and connecting the brake relay............................................................................ 107
8.3.9 For standard rail mounting ................................................................................................... 108
8.3.10 Shield connection kit ............................................................................................................ 108

Table of contents
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A Appendix............................................................................................................................................. 109
A.1 Manuals and technical support .............................................................................................109
A.1.1 Overview of the manuals ......................................................................................................109
A.1.2 Configuring support...............................................................................................................111
A.1.3 Product Support ....................................................................................................................112
A.2 Disposal ................................................................................................................................113
A.3 Directives and standards ......................................................................................................114
A.4 Abbreviations ........................................................................................................................116
Index................................................................................................................................................... 117

Table of contents
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Power Modules PM240
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Changes in this manual
1
Changes with respect to the manual, Edition 07/2009
All chapters in the manual have been completely revised.

Changes in this manual
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Fundamental safety instructions
2
2.1
General safety instructions
DANGER
Danger to life due to live parts and other energy sources
Death or serious injury can result when live parts are touched.
•Only work on electrical devices when you are qualified for this job.
•Always observe the country-specific safety rules.
Generally, six steps apply when establishing safety:
1. Prepare for shutdown and notify all those who will be affected by the procedure.
2. Disconnect the machine from the supply.
–Switch off the machine.
–Wait until the discharge time specified on the warning labels has elapsed.
–Check that it really is in a no-voltage condition, from phase conductor to phase
conductor and phase conductor to protective conductor.
–Check whether the existing auxiliary supply circuits are de-energized.
–Ensure that the motors cannot move.
3. Identify all other dangerous energy sources, e.g. compressed air, hydraulic systems, or
water.
4. Isolate or neutralize all hazardous energy sources by closing switches, grounding or
short-circuiting or closing valves, for example.
5. Secure the energy sources against switching on again.
6. Ensure that the correct machine is completely interlocked.
After you have completed the work, restore the operational readiness in the inverse
sequence.
WARNING
Danger to life through a hazardous voltage when connecting an unsuitable power supply
Touching live components can result in death or severe injury.
•Only use power supplies that provide SELV (Safety Extra Low Voltage) or PELV-
(Protective Extra Low Voltage) output voltages for all connections and terminals of the
electronics modules.

Fundamental safety instructions
2.1 General safety instructions
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WARNING
Danger to life when live parts are touched on damaged devices
Improper handling of devices can cause damage.
For damaged devices, hazardous voltages can be present at the enclosure or at exposed
components; if touched, this can result in death or severe injury.
•Ensure compliance with the limit values specified in the technical data during transport,
storage and operation.
•Do not use any damaged devices.
WARNING
Danger to life through electric shock due to unconnected cable shields
Hazardous touch voltages can occur through capacitive cross-coupling due to unconnected
cable shields.
•As a minimum, connect cable shields and the conductors of power cables that are not
used (e.g. brake cores) at one end at the grounded housing potential.
WARNING
Danger to life due to electric shock when not grounded
For missing or incorrectly implemented protective conductor connection for devices with
protection class I, high voltages can be present at open, exposed parts, which when
touched, can result in death or severe injury.
•Ground the device in compliance with the applicable regulations.
WARNING
Danger to life due to electric shock when opening plug connections in operation
When opening plug connections in operation, arcs can result in severe injury or death.
•Only open plug connections when the equipment is in a no-voltage state, unless it has
been explicitly stated that they can be opened in operation.
NOTICE
Material damage due to loose power connections
Insufficient tightening torques or vibrations can result in loose electrical connections. This
can result in damage due to fire, device defects or malfunctions.
•Tighten all power connections with the specified tightening torques, e.g. line supply
connection, motor connection, DC link connections.
•Check all power connections at regular intervals. This applies in particular after
transport.

Fundamental safety instructions
2.1 General safety instructions
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WARNING
Danger to life due to fire spreading if housing is inadequate
Fire and smoke development can cause severe personal injury or material damage.
•Install devices without a protective housing in a metal control cabinet (or protect the
device by another equivalent measure) in such a way that contact with fire is prevented.
•Ensure that smoke can only escape via controlled and monitored paths.
WARNING
Danger to life through unexpected movement of machines when using mobile wireless
devices or mobile phones
Using mobile wireless devices or mobile phones with a transmit power > 1 W closer than
approx. 2 m to the components may cause the devices to malfunction, influence the
functional safety of machines therefore putting people at risk or causing material damage.
•Switch the wireless devices or mobile phones off in the immediate vicinity of the
components.
WARNING
Danger to life due to the motor catching fire in the event of insulation overload
There is higher stress on the motor insulation through a ground fault in an IT system. If the
insulation fails, it is possible that death or severe injury can occur as a result of smoke and
fire.
•Use a monitoring device that signals an insulation fault.
•Correct the fault as quickly as possible so the motor insulation is not overloaded.
WARNING
Danger to life due to fire if overheating occurs because of insufficient ventilation clearances
Inadequate ventilation clearances can cause overheating of components with subsequent
fire and smoke. This can cause severe injury or even death. This can also result in
increased downtime and reduced service lives for devices/systems.
•Ensure compliance with the specified minimum clearance as ventilation clearance for
the respective component.
WARNING
Danger of an accident occurring due to missing or illegible warning labels
Missing or illegible warning labels can result in accidents involving death or serious injury.
•Check that the warning labels are complete based on the documentation.
•Attach any missing warning labels to the components, in the national language if
necessary.
•Replace illegible warning labels.

Fundamental safety instructions
2.1 General safety instructions
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NOTICE
Device damage caused by incorrect voltage/insulation tests
Incorrect voltage/insulation tests can damage the device.
•Before carrying out a voltage/insulation check of the system/machine, disconnect the
devices as all converters and motors have been subject to a high voltage test by the
manufacturer, and therefore it is not necessary to perform an additional test within the
system/machine.
WARNING
Danger to life when safety functions are inactive
Safety functions that are inactive or that have not been adjusted accordingly can cause
operational faults on machines that could lead to serious injury or death.
•Observe the information in the appropriate product documentation before
commissioning.
•Carry out a safety inspection for functions relevant to safety on the entire system,
including all safety-related components.
•Ensure that the safety functions used in your drives and automation tasks are adjusted
and activated through appropriate parameterizing.
•Perform a function test.
•Only put your plant into live operation once you have guaranteed that the functions
relevant to safety are running correctly.
Note
Important safety notices for Safety Integrated functions
If you want to use Safety Integrated functions, you must observe the safety notices in the
Safety Integrated manuals.

Fundamental safety instructions
2.2 Safety instructions for electromagnetic fields (EMF)
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2.2
Safety instructions for electromagnetic fields (EMF)
WARNING
Danger to life from electromagnetic fields
Electromagnetic fields (EMF) are generated by the operation of electrical power equipment
such as transformers, converters or motors.
People with pacemakers or implants are at a special risk in the immediate vicinity of these
devices/systems.
•Ensure that the persons involved are the necessary distance away (minimum 2 m).
2.3
Handling electrostatic sensitive devices (ESD)
Electrostatic sensitive devices (ESD) are individual components, integrated circuits, modules
or devices that may be damaged by either electric fields or electrostatic discharge.
NOTICE
Damage through electric fields or electrostatic discharge
Electric fields or electrostatic discharge can cause malfunctions through damaged
individual components, integrated circuits, modules or devices.
•Only pack, store, transport and send electronic components, modules or devices in their
original packaging or in other suitable materials, e.g conductive foam rubber of
aluminum foil.
•Only touch components, modules and devices when you are grounded by one of the
following methods:
–Wearing an ESD wrist strap
–Wearing ESD shoes or ESD grounding straps in ESD areas with conductive flooring
•Only place electronic components, modules or devices on conductive surfaces (table
with ESD surface, conductive ESD foam, ESD packaging, ESD transport container).

Fundamental safety instructions
2.4 Industrial security
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2.4
Industrial security
Note
Industrial security
Siemens provides products and solutions with industrial security functions that support the
secure operation of plants, solutions, machines, equipment and/or networks. They are
important components in a holistic industrial security concept. With this in mind, Siemens’
products and solutions undergo continuous development. Siemens recommends strongly
that you regularly check for product updates.
For the secure operation of Siemens
products and solutions, it is necessary to take suitable
preventive action (e.g. cell protection concept) and integrate each component into a holistic,
state
-of-the-art industrial security concept. Third-party products that may be in use should
also be co
nsidered. For more information about industrial security, visit this address
(
http://www.siemens.com/industrialsecurity).
To stay informed about product updates as they occur, sign up for a prod
uct-specific
newsletter. For more information, visit this address (
http://support.automation.siemens.com
).
WARNING
Danger as a result of unsafe operating states resulting from software manipulation
Software manipulation (e.g. by viruses, Trojan horses, malware, worms) can cause unsafe
operating states to develop in your installation which can result in death, severe injuries
and/or material damage.
•Keep the software up to date.
You will find relevant information and newsletters at this address
(http://support.automation.siemens.com).
•Incorporate the automation and drive components into a holistic, state-of-the-art
industrial security concept for the installation or machine.
You will find further information at this address
(http://www.siemens.com/industrialsecurity).
•Make sure that you include all installed products into the holistic industrial security
concept.
WARNING
Danger to life due to software manipulation when using exchangeable storage media
Storing files onto exchangeable storage media amounts to an increased risk of infection,
e.g. with viruses and malware. As a result of incorrect parameterization, machines can
malfunction, which in turn can lead to injuries or death.
•Protect files stored on exchangeable storage media from malicious software by taking
suitable protection measures, e.g. virus scanners.

Fundamental safety instructions
2.5 Residual risks of power drive systems
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2.5
Residual risks of power drive systems
When assessing the machine- or system-related risk in accordance with the respective local
regulations (e.g., EC Machinery Directive), the machine manufacturer or system installer
must take into account the following residual risks emanating from the control and drive
components of a drive system:
1. Unintentional movements of driven machine or system components during
commissioning, operation, maintenance, and repairs caused by, for example,
–Hardware and/or software errors in the sensors, control system, actuators, and cables
and connections
–Response times of the control system and of the drive
–Operation and/or environmental conditions outside the specification
–Condensation/conductive contamination
–Parameterization, programming, cabling, and installation errors
–Use of wireless devices/mobile phones in the immediate vicinity of electronic
components
–External influences/damage
–X-ray, ionizing radiation and cosmic radiation
2. Unusually high temperatures, including open flames, as well as emissions of light, noise,
particles, gases, etc., can occur inside and outside the components under fault conditions
caused by, for example:
–Component failure
–Software errors
–Operation and/or environmental conditions outside the specification
–External influences/damage
3. Hazardous shock voltages caused by, for example:
–Component failure
–Influence during electrostatic charging
–Induction of voltages in moving motors
–Operation and/or environmental conditions outside 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
For more information about the residual risks of the drive system components, see the
relevant sections in the technical user documentation.

Fundamental safety instructions
2.5 Residual risks of power drive systems
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Power Modules PM240
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Introduction
3
3.1
PM240 Power Modules
Overview
The PM240 Power Modules belong to the modular family of SINAMICS G120 inverters. A
modular inverter comprises Control Unit and Power Module.
The PM240 Power Modules are designed for line voltages of 3 AC 380 V … 480 V.
Depending on the power rating, they are supplied in frame sizes FSA … FSGX.
•
FSA
0.37
kW … 1.5 kW
•
FSB
2.2
kW … 4 kW
•
FSC
7.5
kW … 15 kW
•
FSD
18.5
kW … 30 kW
•
FSE
37 kw
… 45 kW
•
FSF
55
kW … 132 kW
•
FSGX
160
kW … 240 kW
The power data refer to Low Overload operation.
Overload capability of the inverter (Page 63)
Permissible power range of the motors
For the Power Modules, induction motors are permissible in the range from 25 % … 150 %
of the inverter power without any restrictions.
Control Units for the PM240 Power Modules
You can operate the Power Modules with one of the following Control Units.
●CU230P-2 FSGX from V4.3, all other frame sizes without any restriction
●CU240B-2
●CU240E
●CU240E-2
●CU240S
●CU250S-2

Introduction
3.2 Component specification according to UL
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Note
Commissioning the inverter
You must first commis
sion the inverter before you can use it. Commissioning is described in
the operating instructions of the relevant Control Unit.
Overview of the manuals (Page 109)
3.2
Component specification according to UL
The components of the SINAMICS G120 product family are UL-certified. The certification is
indicated on the products using the UL Listing Mark.
If the inverter is protected using semiconductor fuses, then the fuses must be installed in the
same electrical cabinet as the inverter itself.
You can find proof of the certification on the Internet UL certificates (http://www.ul.com)
under "Tools / Online Certifications Directory" by entering the file number or the "Name".
The UL file number for the Power Modules of the SINAMICS G120 product family is:
●E121068 for FSA, FSB and FSC
●E192450 for FSD, FSE, FSF and FSGX