Siemens SINAMICS G120 Assembly instructions

Hardware Installation Manual
08/2016Edition
SINAMICS G120 inverters
PM230 Power Modules, IP20 / push-through technology (PT)
SINAMICS

SINAMICS
SINAMICS G120P
Power Module PM230, IP20 / Push-
through technology (PT)
Hardware Installation Manual
Edition 08/2016
08/2016
A5E34331322B AB
Changes in this manual 1
Fundamental safety
instructions 2
Introduction 3
Installing/mounting 4
Connecting 5
Service and maintenance 6
Technical specifications 7
Spare parts and accessories 8
Appendix A

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.
Siemens AG
Division Digital Factory
Postfach 48 48
90026 NÜRNBERG
GERMANY
A5E34331322B AB
Ⓟ 10/2016 Subject to change
Copyright © Siemens AG 2010 - 2016.
All rights reserved

Table of contents
1 Changes in this manual .............................................................................................................................7
2Fundamental safety instructions...................................................................................................................9
2.1 General safety instructions.......................................................................................................9
2.2 Safety instructions for electromagnetic fields (EMF)..............................................................13
2.3 Handling electrostatic sensitive devices (ESD)......................................................................14
2.4 Industrial security...................................................................................................................15
2.5 Residual risks of power drive systems...................................................................................16
3 Introduction.................................................................................................................................................17
3.1 Component specification according to UL..............................................................................19
3.2 Permissible motors.................................................................................................................20
4 Installing/mounting......................................................................................................................................21
4.1 Installation conditions.............................................................................................................21
4.2 EMC-compliant installation of a plant or machine..................................................................23
4.2.1 Control cabinet.......................................................................................................................24
4.2.2 Cables....................................................................................................................................25
4.2.3 Electromechanical components.............................................................................................28
4.3 Power losses and air cooling requirements...........................................................................29
4.4 Mounting the Power Modules.................................................................................................31
4.4.1 Dimension drawings and drilling dimensions for IP20 Power Modules..................................32
4.4.2 Dimension drawings and drilling dimensions for PT Power Modules.....................................35
4.4.2.1 Mounting the shield plate.......................................................................................................36
4.5 Supplementary components..................................................................................................37
5 Connecting.................................................................................................................................................39
5.1 Permissible line supplies........................................................................................................41
5.1.1 TN line system.......................................................................................................................41
5.1.2 TT line system........................................................................................................................42
5.1.3 IT system................................................................................................................................43
5.1.4 Protective conductor..............................................................................................................44
5.2 Connecting the line and motor cable at the inverter...............................................................46
5.2.1 Connection overview..............................................................................................................46
5.2.2 Inverter terminals...................................................................................................................46
5.2.3 Length of motor cable............................................................................................................47
5.2.4 Establishing connections........................................................................................................47
5.2.5 Connecting the motor to the inverter in a star or delta connection.........................................49
6 Service and maintenance...........................................................................................................................51
6.1 Maintenance...........................................................................................................................52
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6.2 Replacing the cooling fan.......................................................................................................53
7 Technical specifications..............................................................................................................................57
7.1 Overload capability of the inverter..........................................................................................58
7.2 Cable cross-sections and tightening torques.........................................................................60
7.3 Electromagnetic compatibility - overview ..............................................................................61
7.4 Ambient conditions.................................................................................................................62
7.5 General technical data...........................................................................................................63
7.6 Detailed technical data...........................................................................................................64
7.7 Restrictions for special ambient conditions............................................................................69
7.7.1 Current reduction depending on pulse frequency..................................................................70
7.8 Electromagnetic compatibility of variable-speed drives.........................................................71
7.8.1 Inverter applications...............................................................................................................72
7.8.1.1 Operation in the second environment....................................................................................72
7.8.1.2 Operation in the first environment..........................................................................................74
7.8.2 Harmonic currents..................................................................................................................75
7.8.3 EMC limit values in South Korea............................................................................................76
8 Spare parts and accessories......................................................................................................................77
8.1 Product maintenance.............................................................................................................77
8.2 Spare parts.............................................................................................................................78
8.3 Optional accessories..............................................................................................................79
8.3.1 Mounting frames for Power Module with push-through technology.......................................79
8.3.2 Line filters...............................................................................................................................81
8.3.3 Sine-wave filter.......................................................................................................................82
8.3.4 Output reactors......................................................................................................................84
8.3.4.1 Output reactors for inverters FSA ... FSC..............................................................................85
8.3.4.2 Output reactors for inverters FSD ... FSF..............................................................................87
8.3.5 Shield connection kit..............................................................................................................88
A Appendix.....................................................................................................................................................89
A.1 Manuals and technical support..............................................................................................89
A.1.1 Manuals for your inverter.......................................................................................................89
A.1.2 Configuring support................................................................................................................90
A.1.3 Product Support.....................................................................................................................91
A.2 Directives and standards........................................................................................................92
A.3 Abbreviations.........................................................................................................................94
Index...........................................................................................................................................................95
Table of contents
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Changes in this manual 1
Changes with respect to the manual, Edition 06/2014
The new PM230 FSA, FSB and FSC Power Modules support STO.
How can you identify a Power Module of the new series?
From the article number. The devices belonging to the new series have a "G" instead of an
"L" at the last but one position. Otherwise, the article numbers are identical.
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Changes in this manual
Power Module PM230, IP20 / Push-through technology (PT)
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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.
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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
Power Module PM230, IP20 / Push-through technology (PT)
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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.
Fundamental safety instructions
2.1 General safety instructions
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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.
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
2.1 General safety instructions
Power Module PM230, IP20 / Push-through technology (PT)
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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).
Fundamental safety instructions
2.2 Safety instructions for electromagnetic fields (EMF)
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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
2.3 Handling electrostatic sensitive devices (ESD)
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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 considered. 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 product-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
2.4 Industrial security
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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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Introduction 3
Overview
The Power Modules belong to the modular family of SINAMICS G120 inverters. A modular
inverter comprises Control Unit and Power Module.
PM230 Power Modules have been specifically designed for pump and fan drives in industrial
HVAC applications for a line voltage range from 3 AC 380 V … 480 V. The Power Modules
are available as built-in devices or in push-through technology.
They are available with a radio interference suppression filter, Category C2 according to
EN61800-3, or without filter.
Depending on the power rating, they are available in frame sizes FSA … FSF.
● FSA 0.37 kW … 3 kW
● FSB 4 kW … 7.5 kW
● FSC 11 kW … 18.5 kW
● FSD 22 kW … 30 kW
● FSE 37 kW … 45 kW
● FSF 55 kW … 75 kW
The power data refer to Low Overload operation.
Overload capability of the inverter (Page 58)
Control Units for the Power Modules
You can operate the Power Modules with a Control Unit from one of the following listed families
from firmware version 4.4 and higher.
● CU230P-2
● CU240B-2
● CU240E-2
Operation with Control Units other than those listed above is not permitted.
Note
Commissioning the inverter
You must first commission the inverter before you can use it. Commissioning is described in
the operating instructions of the relevant Control Unit.
Manuals for your inverter (Page 89).
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STO with PM230 and CU240
The PM230 FSA … FSC Power Modules have been technically revised. Together with CU240
Control Units from software version V4.7 SP3, they support the STO safety function.
You can identify the new series of Power Modules as a result of the article number. The article
numbers of the new Power Modules have a "G" instead of an "L" at the last but one position.
Otherwise, the article numbers are identical.
Introduction
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3.1 Component specification according to UL
The components of the SINAMICS G120 product family are certified according to UL508C.
The certification is indicated on the products using the UL Listing Mark.
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
The UL file number for the Power Modules of the SINAMICS G120 product family is:
● E192450 for FSD, FSE and FSF
Introduction
3.1 Component specification according to UL
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3.2 Permissible motors
Note
Motors for inverter operation
Only use motors that are suitable for operation with inverters with a DC link.
Permissible motors
For the Power Modules, induction motors are permissible in the range from 25 % … 150 % of
the inverter power without any restrictions.
Introduction
3.2 Permissible motors
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