Siemens SINAMICS G120 Assembly instructions

Hardware Installation
Manual
PM250 Power Module
SINAMICS G120 Converters
04/2021Edition
SINAMICS
www.siemens.com/drives

A5E36265179B-AB
SINAMICS G120
PM250 Power Module
Hardware Installation Manual
Edition 04/2021
04/2021
A5E36265179B-AB
Changes in this manual 1
Fundamental safety
instructions 2
Introduction 3
Installing/mounting 4
Connection 5
Operation, repair, and
maintenance 6
Technical speci󹪝cations 7
Spare parts and accessories 8
Appendix 9

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.
Quali󹪝ed Personnel
The product/system described in this documentation may be operated only by personnel quali󹪝ed for the speci󹪝c
task in accordance with the relevant documentation, in particular its warning notices and safety instructions.
Quali󹪝ed 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 identi󹪝ed 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
Digital Industries
Postfach 48 48
90026 NÜRNBERG
GERMANY
A5E36265179B-AB
Ⓟ 06/2021 Subject to change
Copyright © Siemens AG 2006 - 2021.
All rights reserved

Table of contents
1 Changes in this manual ....................................................................................................................... 5
2 Fundamental safety instructions........................................................................................................... 7
2.1 General safety instructions................................................................................................... 7
2.2 Equipment damage due to electric 󹪝elds or electrostatic discharge ..................................... 13
2.3 Warranty and liability for application examples ................................................................... 14
2.4 Security information .......................................................................................................... 15
2.5 Residual risks of power drive systems ................................................................................. 16
3 Introduction ......................................................................................................................................... 17
4 Installing/mounting ............................................................................................................................. 19
4.1 EMC-compliant installation of a machine or system ............................................................ 19
4.1.1 Control cabinet .................................................................................................................. 20
4.1.2 Cables ............................................................................................................................... 21
4.1.3 Electromechanical components.......................................................................................... 24
4.2 Power losses and air cooling requirements ......................................................................... 25
4.3 Mounting the Power Modules ............................................................................................ 26
4.4 Additional components...................................................................................................... 30
5 Connection........................................................................................................................................... 31
5.1 Permissible networks ......................................................................................................... 33
5.1.1 TN line system ................................................................................................................... 34
5.1.2 TT line system.................................................................................................................... 35
5.1.3 IT system ........................................................................................................................... 36
5.2 Requirements for the protective conductor ......................................................................... 37
5.3 Connection overview ......................................................................................................... 39
5.4 Inverter terminals .............................................................................................................. 41
5.5 Connecting the line supply and motor ................................................................................ 42
5.6 Length of motor cable........................................................................................................ 44
5.7 Connecting the motor to the converter in a star or delta connection ................................... 45
6 Operation, repair, and maintenance ................................................................................................... 47
6.1 Operation .......................................................................................................................... 47
6.2 Repair................................................................................................................................ 48
6.3 Replacing fans ................................................................................................................... 49
6.4 Maintenance...................................................................................................................... 52
PM250 Power Module
Hardware Installation Manual, 04/2021, A5E36265179B-AB 3

7 Technical speci󹪝cations ....................................................................................................................... 53
7.1 Overload capability of the converter................................................................................... 54
7.2 Ambient conditions............................................................................................................ 56
7.3 General technical data, PM250........................................................................................... 57
7.4 Power-dependent data....................................................................................................... 58
7.5 Current derating depending on the pulse frequency ........................................................... 60
7.6 Restrictions for special ambient conditions ......................................................................... 61
7.7 Electromagnetic compatibility of the inverter ..................................................................... 63
7.7.1 Assigning the inverter to EMC categories............................................................................ 64
7.7.2 EMC limit values in South Korea ......................................................................................... 66
8 Spare parts and accessories................................................................................................................. 67
8.1 Spare parts compatibility.................................................................................................... 67
8.2 Spare parts ........................................................................................................................ 68
8.3 Optional accessories .......................................................................................................... 69
8.3.1 Reactors and 󹪝lters as base components............................................................................. 69
8.3.2 Line 󹪝lter ........................................................................................................................... 69
8.3.3 Output reactor ................................................................................................................... 72
8.3.4 Sine-wave 󹪝lter .................................................................................................................. 76
8.3.5 Connecting a motor holding brake ..................................................................................... 79
8.3.5.1 Mounting and connecting the brake relay........................................................................... 79
8.3.5.2 Mounting and connecting the Safe Brake Relay................................................................... 80
8.3.5.3 Technical data of the brake relay ........................................................................................ 80
8.3.5.4 Mounting and connecting the brake relay........................................................................... 80
8.3.6 Shield connection kit ......................................................................................................... 81
9 Appendix.............................................................................................................................................. 83
9.1 Manuals and technical support........................................................................................... 83
9.1.1 Overview of the manuals ................................................................................................... 83
9.1.2 Con󹪝guring support........................................................................................................... 84
9.1.3 Product Support................................................................................................................. 85
9.2 Directives and standards .................................................................................................... 87
Index .................................................................................................................................................... 89
Table of contents
PM250 Power Module
4Hardware Installation Manual, 04/2021, A5E36265179B-AB

Changes in this manual 1
Changes with respect to the manual, edition 01/2016
• Dimension drawing for Power Modules FSD, FSE, FSF corrected.
Mounting the Power Modules (Page 26)
• Degree of protection for output reactors corrected.
Assignment of converter FSD (18.5 kW and 22 kW) and output reactors corrected.
Output reactor (Page 72)
• Information on the minimum line impedance added.
General technical data, PM250 (Page 57)
• Incorrect information about line harmonics removed.
Electromagnetic compatibility of the inverter (Page 63)
• Incorrect information about maximum conductor cross-section for Power Module FSE
corrected.
Inverter terminals (Page 41)
• Information on overcurrent protective devices added.
Power-dependent data (Page 58)
PM250 Power Module
Hardware Installation Manual, 04/2021, A5E36265179B-AB 5

Changes in this manual
PM250 Power Module
6Hardware Installation Manual, 04/2021, A5E36265179B-AB

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 quali󹪝ed for this job.
• Always observe the country-speci󹪝c safety rules.
Generally, the following steps apply when establishing safety:
1. Prepare for disconnection. Notify all those who will be a󹪜ected 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 speci󹪝ed 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
Risk of electric shock and 󹪝re from supply networks with an excessively high impedance
Excessively low short-circuit currents can lead to the protective devices not tripping or tripping
too late, and thus causing electric shock or a 󹪝re.
• In the case of a conductor-conductor or conductor-ground short-circuit, ensure that the
short-circuit current at the point where the converter is connected to the line supply at least
meets the minimum requirements for the response of the protective device used.
• You must use an additional residual-current device (RCD) if a conductor-ground short circuit
does not reach the short-circuit current required for the protective device to respond. The
required short-circuit current can be too low, especially for TT supply systems.
PM250 Power Module
Hardware Installation Manual, 04/2021, A5E36265179B-AB 7

WARNING
Risk of electric shock and 󹪝re from supply networks with an excessively low impedance
Excessively high short-circuit currents can lead to the protective devices not being able to
interrupt these short-circuit currents and being destroyed, and thus causing electric shock or a
󹪝re.
• Ensure that the prospective short-circuit current at the line terminal of the converter does
not exceed the breaking capacity (SCCR or Icc) of the protective device used.
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
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. Contact with hazardous voltage can result in severe 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.
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 speci󹪝ed in the technical data during transport,
storage and operation.
• Do not use any damaged devices.
Fundamental safety instructions
2.1 General safety instructions
PM250 Power Module
8Hardware Installation Manual, 04/2021, A5E36265179B-AB

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
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 o󹪜. 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.
NOTICE
Damage to equipment due to unsuitable tightening tools.
Unsuitable tightening tools or fastening methods can damage the screws of the equipment.
• Be sure to only use screwdrivers which exactly match the heads of the screws.
• Tighten the screws with the torque speci󹪝ed in the technical documentation.
• Use a torque wrench or a mechanical precision nut runner with a dynamic torque sensor and
speed limitation system.
NOTICE
Property damage due to loose power connections
Insu󹪟cient tightening torques or vibration can result in loose power connections. This can
result in damage due to 󹪝re, 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.
Fundamental safety instructions
2.1 General safety instructions
PM250 Power Module
Hardware Installation Manual, 04/2021, A5E36265179B-AB 9

WARNING
Spread of 󹪝re from built-in devices
In the event of 󹪝re outbreak, the enclosures of built-in devices cannot prevent the escape of
󹪝re 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 󹪝re and smoke, or take other appropriate measures to protect personnel.
• Ensure that smoke can only escape via controlled and monitored paths.
WARNING
Active implant malfunctions due to electromagnetic 󹪝elds
Converters generate electromagnetic 󹪝elds (EMF) in operation. Electromagnetic 󹪝elds may
interfere with active implants, e.g. pacemakers. People with active implants in the immediate
vicinity of an converter are at risk.
• As the operator of an EMF-emitting installation, assess the individual risks of persons with
active implants.
• Observe the data on EMF emission provided in the product documentation.
WARNING
Unexpected movement of machines caused by radio devices or mobile phones
Using radio devices or mobile telephones in the immediate vicinity of the components can
result in equipment malfunction. Malfunctions may impair the functional safety of machines
and can therefore put people in danger or lead to property damage.
• Therefore, if you move closer than 20 cm to the components, be sure to switch o󹪜 radio
devices or mobile telephones.
• Use the "SIEMENS Industry Online Support app" only on equipment that has already been
switched o󹪜.
NOTICE
Damage to motor insulation due to excessive voltages
When operated on systems with grounded line conductor or in the event of a ground fault in
the IT system, the motor insulation can be damaged by the higher voltage to ground. If you use
motors that have insulation that is not designed for operation with grounded line conductors,
you must perform the following measures:
• IT system: Use a ground fault monitor and eliminate the fault as quickly as possible.
• TN or TT systems with grounded line conductor: Use an isolating transformer on the line
side.
Fundamental safety instructions
2.1 General safety instructions
PM250 Power Module
10 Hardware Installation Manual, 04/2021, A5E36265179B-AB

WARNING
Fire due to inadequate ventilation clearances
Inadequate ventilation clearances can cause overheating of components with subsequent 󹪝re
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 speci󹪝ed minimum clearance as ventilation clearance for the
respective component.
NOTICE
Overheating due to inadmissible mounting position
The device may overheat and therefore be damaged if mounted in an inadmissible position.
• Only operate the device in admissible mounting positions.
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
PM250 Power Module
Hardware Installation Manual, 04/2021, A5E36265179B-AB 11

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
PM250 Power Module
12 Hardware Installation Manual, 04/2021, A5E36265179B-AB

2.2 Equipment damage due to electric 󹪝elds or electrostatic discharge
Electrostatic sensitive devices (ESD) are individual components, integrated circuits, modules or
devices that may be damaged by either electric 󹪝elds or electrostatic discharge.
NOTICE
Equipment damage due to electric 󹪝elds or electrostatic discharge
Electric 󹪝elds 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 󹪞ooring
• 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 󹪝elds or electrostatic discharge
PM250 Power Module
Hardware Installation Manual, 04/2021, A5E36265179B-AB 13

2.3 Warranty and liability for application examples
Application examples are not binding and do not claim to be complete regarding con󹪝guration,
equipment or any eventuality which may arise. Application examples do not represent speci󹪝c
customer solutions, but are only intended to provide support for typical tasks.
As the user you yourself are responsible for ensuring that the products described are operated
correctly. 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
PM250 Power Module
14 Hardware Installation Manual, 04/2021, A5E36265179B-AB

2.4 Security information
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 constitute one element of such a concept.
Customers are responsible for preventing unauthorized access to their plants, systems,
machines and networks. Such systems, machines and components should only be connected to
an enterprise network or the internet if and to the extent such a connection is necessary and only
when appropriate security measures (e.g. 󹪝rewalls and/or network segmentation) are in place.
For additional information on industrial security measures that may be implemented, please
visit
https://www.siemens.com/industrialsecurity (https://www.siemens.com/industrialsecurity).
Siemens’ products and solutions undergo continuous development to make them more secure.
Siemens strongly recommends that product updates are applied as soon as they are available
and that the latest product versions are used. Use of product versions that are no longer
supported, and failure to apply the latest updates may increase customer’s exposure to cyber
threats.
To stay informed about product updates, subscribe to the Siemens Industrial Security RSS Feed
under
https://www.siemens.com/industrialsecurity (https://new.siemens.com/global/en/products/
services/cert.html#Subscriptions).
Further information is provided on the Internet:
Industrial Security Con󹪝guration Manual (https://support.industry.siemens.com/cs/ww/en/
view/108862708)
WARNING
Unsafe operating states resulting from software manipulation
Software manipulations, e.g. viruses, Trojans, 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 󹪝les stored on exchangeable storage media from malicious software by with suitable
protection measures, e.g. virus scanners.
• On completion of commissioning, check all security-related settings.
Fundamental safety instructions
2.4 Security information
PM250 Power Module
Hardware Installation Manual, 04/2021, A5E36265179B-AB 15

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 speci󹪝cation
– Condensation/conductive contamination
– Parameterization, programming, cabling, and installation errors
– Use of wireless devices/mobile phones in the immediate vicinity of electronic components
– External in󹪞uences/damage
– X-ray, ionizing radiation and cosmic radiation
2. Unusually high temperatures, including open 󹪞ames, 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 speci󹪝cation
– External in󹪞uences/damage
3. Hazardous shock voltages caused by, for example:
– Component failure
–In󹪞uence during electrostatic charging
– Induction of voltages in moving motors
– Operation and/or environmental conditions outside the speci󹪝cation
– Condensation/conductive contamination
– External in󹪞uences/damage
4. Electrical, magnetic and electromagnetic 󹪝elds 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. In󹪞uence 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
PM250 Power Module
16 Hardware Installation Manual, 04/2021, A5E36265179B-AB

Introduction 3
Description
The Power Module is part of the modular SINAMICS G120 converter family. A converter consists
of a Control Unit and a Power Module.
You can operate the Power Module with one of the following Control Units.
• CU230P-2
• CU240B-2
• CU240E-2
• CU250S-2
A characteristic feature of the Power Module is dynamic regenerative braking with energy
feedback into the grid.
The Power Module is designed for mains voltages of 380 V to 480 V 3 AC. Depending on the
power rating, the Power Modules are supplied in frame sizes FSC to FSF.
The degree of protection is IP20.
• FSC 7.5 kW … 15 kW
• FSD 18.5 kW … 30 kW
• FSE 37 kW … 46 kW
• FSF 55 kW … 90 kW
The speci󹪝ed power ratings refer to Low Overload operation.
Technical speci󹪝cations (Page 53)
More information
Note
Commissioning the converter
You must 󹪝rst commission the converter before you can use it. Commissioning is described in the
operating instructions of the relevant Control Unit.
Manuals and technical support (Page 83)
PM250 Power Module
Hardware Installation Manual, 04/2021, A5E36265179B-AB 17

Permissible motors
Note
Motors for converter operation
Only use motors that are suitable for operation with converters with a DC link.
For the Power Modules, induction motors are permissible in the range from 25% … 150% of the
converter power without any restrictions.
Introduction
PM250 Power Module
18 Hardware Installation Manual, 04/2021, A5E36265179B-AB