Siemens SINAMICS PM240-2 Assembly instructions

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SINAMICS
SINAMICS G120
Power Module PM240-2
Hardware Installation Manual
01/2017
01/2017
A5E33294624B AE
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
8
Accessories
9
Appendix
A

Siemens AG
Divisi
on Digital Factory
Postfach 48 48
90026 NÜRNBERG
GERMANY
A5E33294624B AE
Ⓟ
02/2017 Subject to change
Copyright © Siemens AG 2013 - 2017.
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 Handling electrostatic sensitive devices (ESD) ......................................................................16
2.3 Industrial security ....................................................................................................................17
2.4 Residual risks of power drive systems....................................................................................18
3 Introduction........................................................................................................................................... 19
3.1 Component specification according to UL ..............................................................................20
3.2 Permissible motors .................................................................................................................20
4 Installing/mounting ................................................................................................................................ 21
4.1 Installation conditions..............................................................................................................21
4.2 EMC-compliant installation of a machine or system...............................................................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 built-in units - IP20 devices ........................33
4.4.2 Hoisting gear FSD ... FSF.......................................................................................................35
4.4.3 Mounting the shield plate for built-in units ..............................................................................35
4.4.4 Dimension drawings and drilling dimensions for PT Power Modules.....................................38
4.4.5 Mounting the shield plate for PT Power Modules ...................................................................39
4.5 Additional components............................................................................................................39
5 Connecting-up ...................................................................................................................................... 41
5.1 Permissible line supplies ........................................................................................................44
5.1.1 TN line system ........................................................................................................................44
5.1.2 TT line system.........................................................................................................................45
5.1.3 IT system ................................................................................................................................46
5.1.4 Protective conductor ...............................................................................................................47
5.2 Connecting the line and motor cable at the inverter ...............................................................49
5.2.1 Connection overview...............................................................................................................49
5.2.2 Length of the motor cable .......................................................................................................52
5.2.3 Connection terminals at the inverter .......................................................................................53
5.2.4 Establishing connections ........................................................................................................54
5.3 STO via Power Module terminals ...........................................................................................57
5.4 Connecting the motor to the inverter in a star or delta connection.........................................58

Table of contents
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6 Service and maintenance...................................................................................................................... 59
6.1 Maintenance........................................................................................................................... 60
6.2 Commissioning after a long storage time .............................................................................. 61
6.3 Replacing a fan ...................................................................................................................... 62
6.3.1 Fan replacement FSA … FSC ............................................................................................... 62
6.3.2 Fan replacement FSD … FSF ............................................................................................... 63
7 Technical data ...................................................................................................................................... 65
7.1 Electromagnetic compatibility - Overview .............................................................................. 65
7.2 Ambient conditions................................................................................................................. 66
7.3 Overload capability of the inverter ......................................................................................... 68
7.4 Cable cross-sections and tightening torques......................................................................... 70
7.5 Technical data, 200 V inverters ............................................................................................. 71
7.5.1 General data, 200 V inverters ................................................................................................ 71
7.5.2 Specific technical data, 200 V inverters................................................................................. 73
7.5.3 Current derating depending on the pulse frequency, 200 V inverters ................................... 78
7.6 Technical data, 400 V inverters ............................................................................................. 79
7.6.1 General data, 400 V inverters ................................................................................................ 79
7.6.2 Specific technical data, 400 V inverters................................................................................. 81
7.6.3 Current derating depending on the pulse frequency, 400 V inverters ................................... 87
7.7 Technical data, 690 V inverters ............................................................................................. 88
7.7.1 General data, 690 V inverters ................................................................................................ 88
7.7.2 Specific technical data, 690 V inverters................................................................................. 90
7.7.3 Current derating depending on the pulse frequency, 690 V inverters ................................... 92
7.8 Restrictions for special ambient conditions............................................................................ 93
7.9 Electromagnetic compatibility of variable-speed drives......................................................... 96
7.9.1 Inverter applications............................................................................................................... 97
7.9.1.1 Operation in the Second Environment................................................................................... 97
7.9.1.2 Operation in the First Environment ........................................................................................ 99
7.9.2 Typical harmonic currents.................................................................................................... 100
7.9.3 EMC limit values in South Korea ......................................................................................... 101
8 Spare parts ..........................................................................................................................................103
9 Accessories .........................................................................................................................................105
9.1 Top shield plate - FSD … FSF............................................................................................. 106
9.2 Mounting frames for PT power modules.............................................................................. 107
9.3 Line reactor .......................................................................................................................... 109
9.4 Line filter............................................................................................................................... 113
9.5 Braking resistor .................................................................................................................... 115
9.5.1 Connecting a braking resistor .............................................................................................. 118
9.5.2 Technical data of the braking resistor .................................................................................. 119
9.6 Connecting a motor holding brake....................................................................................... 122
9.6.1 Technical data of the brake relay?....................................................................................... 122
9.6.2 Connections and circuit diagrams........................................................................................ 123

Table of contents
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9.6.3 Mounting and connecting the brake relay.............................................................................124
9.7 Output reactor .......................................................................................................................125
9.8 Voltage limiter and du/dt filter ...............................................................................................130
A Appendix............................................................................................................................................. 133
A.1 Manuals and technical support .............................................................................................133
A.1.1 Manuals for your inverter ......................................................................................................133
A.1.2 Configuring support...............................................................................................................134
A.1.3 Product Support ....................................................................................................................135
A.2 Disposal ................................................................................................................................136
A.3 Directives and standards ......................................................................................................137
A.4 Abbreviations ........................................................................................................................139
Index................................................................................................................................................... 141

Table of contents
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Power Module PM240-2
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Changes in this manual
1
With respect to the PM240-2 Power Modules Manual, Edition 12/2015
The "EMC-compliant installation" section has been revised and moved to the
"Installation/mounting" chapter. It now has the title "EMC-compliant installation of a machine
or system".
The "Installing Power Modules" section has been revised.
The "Connecting" chapter has been restructured. "Connecting the motor to the inverter in a
star or delta connection" section has been revised.
The "Technical data" chapter has been revised and restructured.

Changes in this manual
Power Module PM240-2
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Power Module PM240-2
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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.
WARNING
Danger to life through electric shock due to the residual charge of the power component
capacitors
Because of the capacitors, a hazardous voltage is present for up to 5 minutes after the
power supply has been switched off. Contact with live parts can result in death or serious
injury.
•Wait for 5 minutes before you check that the unit really is in a no-voltage condition and
start work.

Fundamental safety instructions
2.1 General safety instructions
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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.
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 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 particular risk in the immediate vicinity of this
equipment.
•If you have a heart pacemaker or implant, maintain a minimum distance of 2 m from
electrical power equipment.
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.

Fundamental safety instructions
2.1 General safety instructions
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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.
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.

Fundamental safety instructions
2.1 General safety instructions
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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 Handling electrostatic sensitive devices (ESD)
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2.2
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 Industrial security
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2.3
Industrial security
Note
Industrial security
Siemens provides products and solutions with industrial security functions that support the
secure operation of plants, systems, machines and networks.
In order to protect plants, systems, machines and networks against cyber threats, it is
necess
ary to implement – and continuously maintain – a holistic, state-of-the-art industrial
security concept. Siemens products and solutions only represent one component of such a
concept.
The customer is responsible for preventing unauthorized access to its pl
ants, systems,
machines and networks. Systems, machines and components should only be connected to
the enterprise network or the internet if and to the extent necessary and with appropriate
security measures (e.g. use of firewalls and network segmentation)
in place.
Additionally, Siemens’ guidance on appropriate security measures should be taken into
account. For more information about industrial security, please visit:
Industrial security (
http://www.siemens.com/industrialsecurity).
Siemens’ products and solutions undergo continuous development to make them more
secure. Siemens strongly recommends to apply product updates as soon as available and to
always use the latest product versions. Use of product versions that are no longer supported,
and failure to apply latest updates may increase customer’s exposure to cyber threats.
To stay informed about product updates, subscribe to the Siemens Industrial Security RSS
Feed at:
Industrial security (
http://www.siemens.com/industrialsecurity).
WARNING
Danger to life as a result of unsafe operating states resulting from software manipulation
Software manipulations (e.g. viruses, trojans, malware or worms) can cause unsafe
operating states in your system that may lead to death, serious injury, and property
damage.
•Keep the software up to date.
•Incorporate the automation and drive components into a holistic, state-of-the-art
industrial security concept for the installation or machine.
•Make sure that you include all installed products into the holistic industrial security
concept.
•Protect files stored on exchangeable storage media from malicious software by with
suitable protection measures, e.g. virus scanners.

Fundamental safety instructions
2.4 Residual risks of power drive systems
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2.4
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
6. Influence of network-connected communication systems, e.g. ripple-control transmitters
or data communication via the network
For more information about the residual risks of the drive system components, see the
relevant sections in the technical user documentation.

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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.
Depending on the power rating in frame sizes FSA … FSF, the following Power Module
versions are supplied:
•
1 AC 200 V
0.55
kW … 4 kW
for line voltages from 1
AC 200 V … 240 V
•
3 AC 200 V
0.55
kW … 55 kW
for line voltages from 3
AC 200 V … 240 V
•
3 AC 400 V
0.55
kW … 132 kW
for line voltages from 3
AC 380 V … 480 V
•
3 AC 690 V
1
1 kW … 132 kW
for line voltages from 3
AC 500 V … 690 V
Control Units for the Power Modules
You can operate the Power Modules with a Control Unit from one of the following listed
families.
●CU230P-2
●CU240B-2
●CU240E-2
●CU250S-2
For Power Modules FSA … FSC, you require a Control Unit with firmware version V4.4 or
higher.
For Power Modules FSD … FSF, you require a Control Unit with firmware version V4.7 HF8
or higher.
Note
Commissioning the inverter
You must first commission the inverter before you can use i
t. Commissioning is described in
the Operating Instructions of the relevant Control Unit.
Manuals for your inverter (Page 133)
STO independent of the Control Unit
Using the PM240-2 Power Modules, frame sizes FSD, FSE and FSF, you can implement the
"Safe Torque Off" safety function (STO), corresponding to PL e according to EN 13849-1
and SIL 3 according to IEC61508.
STO via Power Module terminals (Page 57).

Introduction
3.1 Component specification according to UL
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3.1
Component specification according to UL
The inverters have UL approval according to UL508C and CSA C22.2 No. 274-13.
Further information and a link for downloading the appropriate certificates can be found in
the following Section:
Directives and standards (Page 137)
3.2
Permissible motors
Note
Motors for inverter operation
Only use motors that are suitable for operation with inverters with a DC link.
Motors for 200 V Power Modules
For the 200 V Power Modules, induction motors are permissible in the range from
25% … 150% of the inverter power without any restrictions.
Motors for 400 V Power Modules
For the 400 V Power Modules, induction motors are permissible in the range from
25 % … 150 % of the inverter power without any restrictions.
Motors for 690 V Power Modules
For the 690 V Power Modules, induction motors are permissible in the range from 50
% … 150 % of the inverter power without any restrictions.