Siemens SINAMICS G12 Assembly instructions

Hardware Installation
Manual
PM240-2 Power Modules,
IP20 / push-through technology (PT)
SINAMICS G120 frequency converters
08/2017Edition
SINAMICS
www.siemens.com/drives

SINAMICS
SINAMICS G120
Power Module PM240-2
Hardware Installation Manual
08/2017
08/2017
A5E33294624B AG
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

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
A5E33294624B AG
Ⓟ 09/2017 Subject to change
Copyright © Siemens AG 2013 - 2017.
All rights reserved

Table of contents
1 Changes in this manual................................................................................................................................9
2Fundamental safety instructions.................................................................................................................11
2.1 General safety instructions.....................................................................................................11
2.2 Equipment damage due to electric fields or electrostatic discharge......................................16
2.3 Warranty and liability for application examples......................................................................17
2.4 Industrial security...................................................................................................................18
2.5 Residual risks of power drive systems...................................................................................19
3 Introduction.................................................................................................................................................21
3.1 Permissible motors.................................................................................................................22
4 Installing/mounting......................................................................................................................................23
4.1 Installation conditions.............................................................................................................23
4.2 EMC-compliant installation of a machine or system..............................................................26
4.2.1 Control cabinet.......................................................................................................................27
4.2.2 Cables....................................................................................................................................28
4.2.3 Electromechanical components.............................................................................................31
4.3 Power losses and air cooling requirements...........................................................................32
4.4 Mounting the Power Modules.................................................................................................33
4.4.1 Sequence for installing the Power Module.............................................................................34
4.4.2 Dimension drawings and drilling dimensions for built-in units - IP20 devices........................35
4.4.3 Dimension drawings and drilling dimensions for PT Power Modules.....................................37
4.4.4 Mounting the shield plates.....................................................................................................41
4.4.5 Hoisting gear FSD ... PSF......................................................................................................44
4.5 Additional components...........................................................................................................45
5 Connecting-up............................................................................................................................................47
5.1 Permissible line supplies........................................................................................................50
5.1.1 TN line system.......................................................................................................................50
5.1.2 TT line system........................................................................................................................51
5.1.3 IT system................................................................................................................................52
5.1.4 Protective conductor..............................................................................................................53
5.2 Connecting the line and motor cable at the inverter...............................................................55
5.2.1 Connection overview..............................................................................................................55
5.2.2 Length of the motor cable......................................................................................................59
5.2.3 Connection terminals at the inverter......................................................................................60
5.2.4 Establishing connections........................................................................................................61
5.3 STO via Power Module terminals...........................................................................................64
5.4 Connecting the motor to the inverter in a star or delta connection.........................................66
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6 Service and maintenance...........................................................................................................................67
6.1 Maintenance...........................................................................................................................68
6.2 Commissioning after a long storage time...............................................................................69
6.3 Replacing a fan......................................................................................................................70
6.3.1 Fan replacement FSA … FSC...............................................................................................70
6.3.2 Fan replacement FSD … FSF................................................................................................71
7 Technical data............................................................................................................................................73
7.1 Electromagnetic compatibility - Overview .............................................................................74
7.2 Ambient conditions.................................................................................................................75
7.3 Overload capability of the inverter..........................................................................................77
7.4 Cable cross-sections and tightening torques ((PM240-2)).....................................................79
7.5 Technical data, 200 V inverters..............................................................................................80
7.5.1 General data, 200 V inverters................................................................................................80
7.5.2 Specific technical data, 200 V inverters.................................................................................82
7.5.3 Current derating depending on the pulse frequency, 200 V inverters....................................89
7.6 Technical data, 400 V inverters..............................................................................................90
7.6.1 General data, 400 V inverters................................................................................................90
7.6.2 Specific technical data, 400 V inverters.................................................................................92
7.6.3 Current derating depending on the pulse frequency, 400 V inverters..................................100
7.7 Technical data, 690 V inverters............................................................................................101
7.7.1 General data, 690 V inverters..............................................................................................101
7.7.2 Specific technical data, 690 V inverters...............................................................................103
7.7.3 Current derating depending on the pulse frequency, 690 V inverters..................................107
7.8 Restrictions for special ambient conditions..........................................................................108
7.9 Electromagnetic compatibility of variable-speed drives.......................................................111
7.9.1 Inverter applications.............................................................................................................112
7.9.1.1 Operation in the Second Environment.................................................................................112
7.9.1.2 Operation in the First Environment......................................................................................114
7.9.2 Typical harmonic currents....................................................................................................115
7.9.3 EMC limit values in South Korea..........................................................................................116
8 Spare parts...............................................................................................................................................117
9 Accessories..............................................................................................................................................119
9.1 Top shield plate - FSD … FSF.............................................................................................120
9.2 Mounting frames for PT power modules..............................................................................121
9.2.1 Mounting instructions with mounting frame..........................................................................124
9.3 Mounting grips for PT Power Modules.................................................................................125
9.4 Line reactor..........................................................................................................................126
9.5 Line filter...............................................................................................................................129
9.6 Braking resistor....................................................................................................................131
9.6.1 Connecting a braking resistor..............................................................................................134
9.6.2 Technical data of the braking resistor..................................................................................135
Table of contents
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9.7 Connecting a motor holding brake.......................................................................................138
9.7.1 Technical data of the brake relay?.......................................................................................138
9.7.2 Connections and circuit diagrams........................................................................................139
9.7.3 Mounting and connecting the brake relay............................................................................140
9.8 Output reactor......................................................................................................................141
9.9 Voltage limiter and du/dt filter...............................................................................................146
A Appendix...................................................................................................................................................149
A.1 Manuals and technical support............................................................................................149
A.1.1 Manuals for your inverter.....................................................................................................149
A.1.2 Configuring support..............................................................................................................150
A.1.3 Product Support...................................................................................................................151
A.2 Disposal...............................................................................................................................152
A.3 Directives and standards......................................................................................................153
A.4 Abbreviations.......................................................................................................................155
Index.........................................................................................................................................................157
Table of contents
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Table of contents
Power Module PM240-2
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Changes in this manual 1
Changes with respect to Edition 01/2017
The Power Modules with push-through technology (PT Power Module), frame sizes
FSD ... FSF, have been integrated.
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Changes in this manual
Power Module PM240-2
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Fundamental safety instructions 2
2.1 General safety instructions
WARNING
Electric shock and danger to life due to other energy sources
Touching live components can result in death or severe injury.
● Only work on electrical devices when you are qualified for this job.
● Always observe the country-specific safety rules.
Generally, the following six steps apply when establishing safety:
1. Prepare for disconnection. Notify all those who will be affected by the procedure.
2. Isolate the drive system from the power supply and take measures to prevent it being
switched back on again.
3. Wait until the discharge time specified on the warning labels has elapsed.
4. Check that there is no voltage between any of the power connections, and between any
of the power connections and the protective conductor connection.
5. Check whether the existing auxiliary supply circuits are de-energized.
6. Ensure that the motors cannot move.
7. Identify all other dangerous energy sources, e.g. compressed air, hydraulic systems, or
water. Switch the energy sources to a safe state.
8. Check that the correct drive system is completely locked.
After you have completed the work, restore the operational readiness in the inverse sequence.
WARNING
Electric shock due to connection to an unsuitable power supply
When equipment is connected to an unsuitable power supply, exposed components may
carry a hazardous voltage that might result in serious injury or death.
● 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
Electric shock due to equipment damage
Improper handling may cause damage to equipment. 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
Electric shock due to unconnected cable shield
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
Electric shock if there is no ground connection
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
Arcing when a plug connection is opened during operation
Opening a plug connection when a system is operation can result in arcing that may cause
serious injury or death.
● Only open plug connections when the equipment is in a voltage-free state, unless it has
been explicitly stated that they can be opened in operation.
WARNING
Electric shock due to residual charges in power components
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
Property damage due to loose power connections
Insufficient tightening torques or vibration can result in loose power connections. This can
result in damage due to fire, device defects or malfunctions.
● Tighten all power connections to the prescribed torque.
● Check all power connections at regular intervals, particularly after equipment has been
transported.
WARNING
Spread of fire from built-in devices
In the event of fire outbreak, the enclosures of built-in devices cannot prevent the escape of
fire and smoke. This can result in serious personal injury or property damage.
● Install built-in units in a suitable metal cabinet in such a way that personnel are protected
against fire and smoke, or take other appropriate measures to protect personnel.
● Ensure that smoke can only escape via controlled and monitored paths.
WARNING
Failure of pacemakers or implant malfunctions due to 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 in the
immediate vicinity of this equipment are at particular risk.
● If you have a heart pacemaker or implant, maintain a minimum distance of 2 m from
electrical power equipment.
WARNING
Unexpected movement of machines caused by radio devices or mobile phones
When radio devices or mobile phones with a transmission power > 1 W are used in the
immediate vicinity of components, they may cause the equipment to malfunction.
Malfunctions may impair the functional safety of machines and can therefore put people in
danger or lead to property damage.
● If you come closer than around 2 m to such components, switch off any radios or mobile
phones.
● Use the "SIEMENS Industry Online Support App" only on equipment that has already been
switched off.
Fundamental safety instructions
2.1 General safety instructions
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WARNING
Motor 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
Fire due to inadequate 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
Unrecognized dangers due to missing or illegible warning labels
Dangers might not be recognized if warning labels are missing or illegible. Unrecognized
dangers may cause accidents resulting in serious injury or death.
● Check that the warning labels are complete based on the documentation.
● Attach any missing warning labels to the components, where necessary in the national
language.
● 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
Unexpected movement of machines caused by inactive safety functions
Inactive or non-adapted safety functions can trigger unexpected machine movements that
may result in 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
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2.2 Equipment damage due to electric fields or electrostatic discharge
Electrostatic sensitive devices (ESD) are individual components, integrated circuits, modules
or devices that may be damaged by either electric fields or electrostatic discharge.
NOTICE
Equipment damage due to 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
2.2 Equipment damage due to electric fields or electrostatic discharge
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2.3 Warranty and liability for application examples
The application examples are not binding and do not claim to be complete regarding
configuration, equipment or any eventuality which may arise. The application examples do not
represent specific customer solutions, but are only intended to provide support for typical tasks.
You are responsible for the proper operation of the described products. These application
examples do not relieve you of your responsibility for safe handling when using, installing,
operating and maintaining the equipment.
Fundamental safety instructions
2.3 Warranty and liability for application examples
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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, systems, machines and networks.
In order to protect plants, systems, machines and networks against cyber threats, it is
necessary 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 plants, 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
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 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
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.
Fundamental safety instructions
2.5 Residual risks of power drive systems
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Fundamental safety instructions
2.5 Residual risks of power drive systems
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