Siemens SINAMICS G150 User manual

Operating Manual Edition 11/2003
sinamics
Converter Cabinet Units
SINAMICS G150
75 kW to 800 kW

SINAMICS G150
Versions A and C
Operating Instructions
User Documentation
Valid for
Converter Type Closed-Loop Control Version
SINAMICS G150 V1.3
Edition 11/03
Safety Notes 1
Device Overview 2
Mechanical Installation 3
Electrical Installation 4
Commissioning 5
Operation 6
Setpoint Channel and
Closed-Loop Control
7
Output Terminals 8
Monitoring, Functions,
and Protective
Functions
9
Diagnosis / Faults and
Alarms
10
Maintenance and
Servicing
11
Technical Data 12
Index

11/03 Contents
SINAMICS G150
ii Operating Manual
For further information please visit us at:
http://www.ad.siemens.de
The reproduction, transmission or use of this
document or its contents is not permitted without
express written authority.
Offenders will be liable for damages. All rights,
including rights created by patent grant or registration
or a utility model or design, are reserved.
© Siemens AG 2003. All rights reserved.
We have conscientiously checked the contents of this
manual to ensure that they coincide with the hardware and
software described. Since deviations cannot be precluded
entirely, we cannot guarantee complete conformance.
However, the data in this manual is reviewed regularly and
any necessary corrections included in subsequent editions.
We are thankful for any recommendations or suggestions.
We reserve the right to make technical changes.
Siemens-Aktiengesellschaft

11/03 Contents
SINAMICS G150
Operating Manual iii
Preface
User Documentation
WARNING
Before installing and commissioning the converter, make sure that you read all the
safety notes and warnings carefully, including the warning labels on the equipment
itself. The warning labels must always be legible. Missing or damaged labels must
be replaced.
Further information is available from:
Technical Support
Tel: [phone]
Fax: [phone]
E-mail [email protected]
Internet Address
Customers can access general and technical information at the following address:
http://www.siemens.com/sinamics.

Contents 11/03
SINAMICS G150
iv Operating Manual
Contents
1 Safety Notes 1-1
1.1 Definitions and Warnings .............................................................................................. 1-1
1.2 Safety and Operating Instructions................................................................................. 1-3
2 Device Overview 2-1
2.1 Chapter Content ............................................................................................................ 2-1
2.2 Applications, Features, Design ..................................................................................... 2-2
2.2.1 Applications ................................................................................................................................. 2-2
2.2.2 Features ...................................................................................................................................... 2-2
2.3 Design ........................................................................................................................... 2-3
2.3.1 Version A ..................................................................................................................................... 2-4
2.3.2 Version C..................................................................................................................................... 2-5
2.4 Wiring Principle ............................................................................................................. 2-6
2.5 Type Plate ..................................................................................................................... 2-7
3 Mechanical Installation 3-1
3.1 Chapter Content ............................................................................................................ 3-1
3.2 Transportation and Storage .......................................................................................... 3-2
3.3 Installation ..................................................................................................................... 3-4
3.3.1 Mechanical Installation: Checklist................................................................................................ 3-4
3.3.2 Preparatory Steps........................................................................................................................ 3-5
3.3.3 Installation ................................................................................................................................... 3-6
3.3.4 Additional Canopies (Option M21) or Hoods (Option M23, M54)................................................. 3-6
3.3.5 Cable Entry from Above (Option M13), Motor Connection from Above (Option M78) ................. 3-9
4 Electrical Installation 4-1
4.1 Chapter Content ............................................................................................................ 4-1
4.2 Electrical Installation: Checklist..................................................................................... 4-2
4.3 Important Safety Precautions........................................................................................ 4-6
4.4 Introduction to EMC....................................................................................................... 4-7
4.5 EMC-Compliant Installation........................................................................................... 4-7
4.6 Power Connections ..................................................................................................... 4-10
4.6.1 Connection Cross-Sections and Cable Lengths ........................................................................ 4-10
4.6.2 Connecting the Motor and Power Cables .................................................................................. 4-11
4.6.3 Adjusting the Fan Voltage (-U1 -T10) ........................................................................................ 4-12
4.6.4 Adjusting the Internal Power Supply (-A1 -T10, Only with Version A) ....................................... 4-14
4.6.5 Removing the Connection Bracket for the Interference-Suppression Capacitor with
Operation from an Ungrounded Supply ..................................................................................... 4-15
4.7 External Supply of the Auxiliary Supply from a Secure Line....................................... 4-16
4.7.1 230 V AC Auxiliary Supply......................................................................................................... 4-17
4.7.2 24 V DC Auxiliary Supply........................................................................................................... 4-17
4.8 Signal Connections ..................................................................................................... 4-18
4.8.1 Customer Terminal Block (-A60) ............................................................................................... 4-18
4.9 Other Connections ...................................................................................................... 4-25
4.9.1 Main Contactor (Option L13) .....................................................................................................4-25
4.9.2 Connection for External Auxiliary Equipment (Option L19)........................................................ 4-26
4.9.3 Main Circuit-Breaker incl. Fuses/Circuit-Breaker (Option L26) .................................................. 4-27
4.9.4 EMERGENCY OFF Button (Option L45) ................................................................................... 4-28

11/03 Contents
SINAMICS G150
Operating Manual v
4.9.5 Cabinet Illumination with Service Socket (Option L50) .............................................................. 4-29
4.9.6 Cabinet Anti-Condensation Heating (Option L55)...................................................................... 4-29
4.9.7 EMERGENCY OFF Category 0; 230 V AC or 24 V DC (Option L57) ........................................ 4-30
4.9.8 EMERGENCY OFF Category 1; 230 V AC (Option L59)........................................................... 4-31
4.9.9 EMERGENCY OFF Category 1; 24 V DC (Option L60)............................................................. 4-32
4.9.10 100 kW Braking Unit (Option L61); 200 kW Braking Unit (Option L62)...................................... 4-33
4.9.11 Thermistor Motor Protection Unit (Option L83/L84) ................................................................... 4-38
4.9.12 PT100 Evaluation Unit (Option L86) .......................................................................................... 4-38
4.9.13 Insulation Monitor (Option L87)) ................................................................................................4-40
5 Commissioning 5-1
5.1 Chapter Content ............................................................................................................ 5-1
5.2 The Operator Panel....................................................................................................... 5-2
5.3 Initial Commissioning .................................................................................................... 5-3
5.3.1 Initial Ramp-Up............................................................................................................................ 5-3
5.3.2 Basic Commissioning .................................................................................................................. 5-4
5.4 Status After Commissioning.......................................................................................... 5-8
5.5 Data Backup.................................................................................................................. 5-9
5.5.1 Saving the CompactFlash Card Parameter Settings ................................................................... 5-9
5.5.2 Restoring the Saved Configuration............................................................................................ 5-10
5.6 Resetting Parameters to the Factory Settings ............................................................ 5-10
6 Operation 6-1
6.1 Chapter Content ............................................................................................................ 6-1
6.2 Control via the Operator Panel...................................................................................... 6-3
6.2.1 Operator Panel (AOP30) Overview ............................................................................................. 6-3
6.2.2 Menu Structure of the Operator Panel ......................................................................................... 6-4
6.2.3 Operation via the Operator Panel (LOCAL Mode) ..................................................................... 6-11
6.2.4 Faults and Alarms...................................................................................................................... 6-16
6.2.5 Saving the Parameters Permanently ......................................................................................... 6-17
6.2.6 Parameterization Errors............................................................................................................. 6-18
6.3 Control via the Terminal Block .................................................................................... 6-19
6.3.1 General...................................................................................................................................... 6-19
6.3.2 Analog Inputs............................................................................................................................. 6-20
6.3.3 Motor Potentiometer .................................................................................................................. 6-23
6.3.4 Fixed Speed Setpoints............................................................................................................... 6-25
6.3.5 Further Settings for Analog Inputs ............................................................................................. 6-27
6.4 Control via PROFIBUS................................................................................................ 6-29
6.4.1 PROFIBUS Connection .............................................................................................................6-29
6.4.2 Control via PROFIBUS .............................................................................................................. 6-32
6.4.3 Process Data ............................................................................................................................. 6-33
7 Setpoint Channel and Closed-Loop Control 7-1
7.1 Chapter Content ............................................................................................................ 7-1
7.2 Setpoint Channel........................................................................................................... 7-2
7.2.1 Direction Reversal ....................................................................................................................... 7-2
7.2.2 Minimum Speed........................................................................................................................... 7-3
7.2.3 Speed Limitation.......................................................................................................................... 7-4
7.2.4 Ramp Generator.......................................................................................................................... 7-5
7.2.5 Further Settings ........................................................................................................................... 7-7
7.3 Closed-Loop Control ..................................................................................................... 7-8
8 Output Terminals 8-1
8.1 Chapter Content ............................................................................................................ 8-1
8.2 Analog Outputs.............................................................................................................. 8-2
8.3 Digital Outputs............................................................................................................... 8-6
8.4 Further Settings for Analog Outputs.............................................................................. 8-8

Contents 11/03
SINAMICS G150
vi Operating Manual
9 Monitoring, Functions, and Protective Functions 9-1
9.1 Chapter Content ............................................................................................................ 9-1
9.2 Monitoring......................................................................................................................9-2
9.3 Functions.......................................................................................................................9-3
9.3.1 Vdc-max Controller ...................................................................................................................... 9-3
9.3.2 Automatic Restart ........................................................................................................................ 9-5
9.3.3 Flying Restart .............................................................................................................................. 9-7
9.4 Protective Functions...................................................................................................... 9-8
10 Diagnosis / Faults and Alarms 10-1
10.1 Chapter Content .......................................................................................................... 10-1
10.2 Troubleshooting........................................................................................................... 10-2
10.2.1 Fault Diagnosis with LEDs......................................................................................................... 10-2
10.2.2 Diagnosis via Parameters.......................................................................................................... 10-4
10.2.3 Indicating and Rectifying Faults................................................................................................. 10-7
10.3 Service and Support.................................................................................................... 10-8
10.4 Alarms and Faults ..................................................................................................... 10-10
10.4.1 "External Warning 1"................................................................................................................ 10-10
10.4.2 "External Fault 1"..................................................................................................................... 10-10
10.4.3 "External Fault 3"..................................................................................................................... 10-11
10.5 List of Faults and Alarms........................................................................................... 10-12
10.5.1 Explanation of the List of Faults and Alarms............................................................................ 10-12
10.5.2 List of Faults and Alarms ......................................................................................................... 10-13
11 Maintenance and Servicing 11-1
11.1 Chapter Content .......................................................................................................... 11-1
11.2 Maintenance................................................................................................................ 11-2
11.2.1 Cleaning .................................................................................................................................... 11-2
11.2.2 Replacing the Filter Mats ........................................................................................................... 11-3
11.3 Servicing...................................................................................................................... 11-3
11.3.1 Replacing the Fan ..................................................................................................................... 11-3
11.3.2 Replacing the Fan Fuses........................................................................................................... 11-4
11.3.3 Replacing the Fuses for the Auxiliary Power Supply (-F11/-F12) .............................................. 11-4
11.3.4 Replacing Fuse -F21 ................................................................................................................. 11-4
11.3.5 Replacing the Cabinet Operator Panel ...................................................................................... 11-5
11.3.6 Replacing the Backup Battery of the Cabinet Operator Panel ................................................... 11-5
11.4 Reforming the DC Link Capacitors.............................................................................. 11-7
11.5 Upgrading the Cabinet Unit Firmware......................................................................... 11-8
11.6 Loading New Operator Panel Firmware and the Database from the PC.................. 11-10
11.7 Using a Replacement CompactFlash Card............................................................... 11-11
12 Technical Data 12-1
12.1 Chapter Content .......................................................................................................... 12-1
12.2 General Data ............................................................................................................... 12-2
12.2.1 Derating Data ............................................................................................................................ 12-3
12.3 Technical Data ............................................................................................................ 12-4
12.3.1 Cabinet Unit Version A, 380 V – 480 V...................................................................................... 12-5
12.3.2 Cabinet Unit Version C, 380 V – 480 V ..................................................................................... 12-8
12.3.3 Cabinet Unit Version A, 660 V – 690 V.................................................................................... 12-11
12.3.4 Cabinet Unit Version C, 660 V – 690 V ................................................................................... 12-16


SINAMICS G150
Operating Manual 1-1
1Safety Notes 1
1.1 Definitions and Warnings
Qualified Personnel
For the purpose of this documentation and the product warning labels, a “qualified
person” is someone who is familiar with the installation, mounting, start-up,
operation and maintenance of the product. He or she must have the following
qualifications:
• Trained or authorized to energize, de-energize, ground, and tag circuits and
equipment in accordance with established safety procedures.
• Training or instruction in the maintenance and use of appropriate safety
equipment in accordance with the technological safety standards.
• First aid training.
DANGER
“Danger” indicates that death, severe personal injury, or substantial property
damage will result if proper precautions are not taken.
WARNING
“Warning” indicates that death, severe personal injury, or substantial property
damage can result if proper precautions are not taken.
CAUTION
“Caution” with a warning triangle indicates that minor personal injury can result if
proper precautions are not taken.

Safety Notes 11/03
SINAMICS G150
1-2 Operating Manual
CAUTION
“Caution” without a warning triangle indicates that material damage can result if
proper precautions are not taken.
IMPORTANT
“Important” indicates that an unwanted result or situation can result if the
appropriate advice is not taken into account.
NOTE
“Note” indicates important information about the product or respective part of the
documentation that is essential to highlight.
WARNING
Hazardous voltages are present in this electrical equipment during operation.
Non-observance of the warnings can result in severe personal injury or property
damage.
Only qualified personnel should work on or around the equipment.
This personnel must be thoroughly familiar with all warning and maintenance
procedures described in this documentation.
The successful and safe operation of this device is dependent on correct transport,
proper storage and installation, as well as careful operation and maintenance.
National safety guidelines must be observed.
Certification
The following certificates can be found under “Safety and Operating Instructions” in
the documentation folder:
• EU declaration of conformity
• Certificate of compliance with order
• EU manufacturer’s declaration

11/03 Safety Notes
SINAMICS G150
Operating Manual 1-3
1.2 Safety and Operating Instructions
DANGER
This equipment is used in industrial high-voltage installations. During operation,
this equipment contains rotating and live, bare parts. For this reason, they could
cause severe injury or significant material damage if the required covers are
removed, if they are used or operated incorrectly, or have not been properly
maintained.
When the machines are used in non-industrial areas, the installation location must
be protected against unauthorized access (protective fencing, appropriate signs).
Prerequisites
Those responsible for protecting the plant must ensure the following:
• The basic planning work for the plant and the transport, assembly, installation,
commissioning, maintenance, and repair work is carried out by qualified
personnel and/or checked by experts responsible.
• The operating instructions and machine documentation are always available.
• The technical data and specifications regarding the applicable installation,
connection, environmental, and operating conditions are always observed.
• The plant-specific assembly and safety guidelines are observed and personal
protection equipment is used.
• Unqualified personnel are forbidden from using these machines and working
near them.
These operating instructions are intended for qualified personnel and only contain
information and notes relating to the intended purpose of the machines.
The operating instructions and machine documentation are written in different
languages as specified in the delivery contracts.
NOTE
The services and support provided by the SIEMENS service centers are
recommended for planning, installation, commissioning, and servicing work.

Safety Notes 11/03
SINAMICS G150
1-4 Operating Manual
Components that can be Destroyed by Electrostatic Discharge (ESD)
CAUTION
The board contains components that can be destroyed by electrostatic discharge.
These components can be easily destroyed if not handled properly. If you do have
to use electronic boards, however, please observe the following:
• You should only touch electronic boards if absolutely necessary.
• If you have to touch boards, however, your body must be electrically discharged
beforehand.
• Boards must not come into contact with highly insulating materials (such as
plastic parts, insulated desktops, articles of clothing manufactured from man-
made fibers).
• Boards must only be placed on conductive surfaces.
• Boards and components should only be stored and transported in conductive
packaging (such as metalized plastic boxes or metal containers).
• If the packaging material is not conductive, the boards must be wrapped with a
conductive packaging material (such as conductive foam rubber or household
aluminum foil).
The necessary ESD protective measures are clearly illustrated in the following
diagram:
• a = conductive floor surface
• b = ESD table
• c = ESD shoes
• d = ESD overall
• e = ESD chain
• f = cubicle ground connection
StandingSitting Sitting / Standing
a
b
e
d
c
d
a
c
d
b
ca
e
f
ff f f
Fig. 1-1 ESD protective measures


SINAMICS G150
Operating Manual 2-1
2Device Overview 2
2.1 Chapter Content
This chapter provides information on the following:
• Introduction to the cabinet units
• The main components and features of the cabinet unit
• The cabinet unit wiring
• Explanation of the type plate

Device Overview 11/03
SINAMICS G150
2-2 Operating Manual
2.2 Applications, Features, Design
2.2.1 Applications
SINAMICS G150 drive converter cabinet units are ideally suited to variable-speed
drives with a quadratic load torque M~n2, such as:
• Pumps
• Fans
• Turbo-compressors
2.2.2 Features
Drives with a quadratic load torque do not normally require a high overload
reserve, nor do they require high-performance closed-loop control with a high
dynamic response, or a speed sensor.
SINAMICS G150 takes this into account and, as a result, offers a low-cost drive
solution tailored to actual requirements.
In addition, factors have been considered to ensure easy handling of the drive from
the planning and design phase through to operation. These factors include:
• Compact, modular, service-friendly design
• Straightforward planning and design
• Ready to connect to facilitate the installation process
• Quick, menu-driven commissioning with no complex parameterization
• Clear and convenient operation via a user-friendly graphical operator panel with
measured values and messages displayed in plain text and a quasi-analog bar
display for measured values.
• SINAMICS is an integral part of Totally Integrated Automation (TIA). The TIA
concept offers an optimized range of products for automation and drive
technology. This concept is characterized by planning / design, communication,
and data management procedures that are consistent throughout the product
range. SINAMICS is totally integrated in the TIA concept.
Quality
The SINAMICS G150 cabinet units are manufactured to meet high standards of
quality and exacting demands.
This results in a high level of reliability, availability, and functionality for our
products.
The development, design, and manufacturing processes, as well as order
processing and the logistics supply center have been independently certified to
DIN ISO 9001.

11/03 Device Overview
SINAMICS G150
Operating Manual 2-3
Service
Our worldwide sales and service network offers our customers individual
consultations, provides support with planning and design, and offers a range of
training courses.
Our Web site offers comprehensive online support with product information,
downloads, operating instructions, and FAQs.
Helplines and field services are available 24 hours a day, 7 days a week, for
support and advice for servicing and ordering spare parts.
2.3 Design
The SINAMICS G150 cabinet units are characterized by their compact, modular,
and service-friendly design.
A wide range of electrical and mechanical components enable the drive system to
be optimized for the appropriate requirements.
Two cabinet unit versions are available depending on the options that are chosen.

Device Overview 11/03
SINAMICS G150
2-4 Operating Manual
2.3.1 Version A
All the required power supply connection components, such as the main circuit-
breaker, circuit-breakers, main contactor, line fuses, radio interference suppression
filter, motor components, and additional protection and monitoring devices, can be
installed as required.
The cabinet unit comprises up to two cabinet panels with a total width of between
800 and 1600 mm, depending on the output.
Door lock
EMERG.OFF (opt.)
Operator panel
Ventilat. grille dep. on
degree of protection
Custumer terminal
block (-A60)
Motor connect. (-X2)
Main circuit-breaker
(-Q1)
Line reactor (-L1)
Power connect. (-X1)
Control unit CU320
(-A10)
Converter (-U1)
Fig. 2-1 Example of a cabinet unit, version A (e.g. 132 kW, 400 V)

11/03 Device Overview
SINAMICS G150
Operating Manual 2-5
2.3.2 Version C
This version is particularly compact in design with an in-built line reactor.
It can be used, for example, when the power supply connection components, such
as the main contactor and main circuit-breaker with fuses for conductor protection
and semi-conductor protection, are installed in an existing central low-voltage
distribution unit (MCC).
The advantage here is that the cabinet unit can be sited decentrally and in the
immediate vicinity of the motor, thereby avoiding the need for long motor cables
and additional output filters.
Line fuses are required for conductor protection (VDE 636, Part 10). Line fuses can
also be used to protect the semi-conductors of the line-commutated converter
(VDE 636, Part 40/ EN 60 269-4).
The cabinet unit simply comprises a single cabinet with a width of 400 mm, 600
mm, or 1000 mm.
Operator panel
Ventilation grille dep.
on degree of
protection
Customer terminal
block (-A60)
Power connection
(-X1)
Door lock
Line reactor (-L1)
Motor connection
(-X2)
Control unit CU320
(-A10)
Converter (-U1)
Fig. 2-2 Example of a cabinet unit, version C (e.g. 315 kW, 690 V)

Device Overview 11/03
SINAMICS G150
2-6 Operating Manual
2.4 Wiring Principle
Wiring principle: versions A and C
1) From an output current of > 800 A, the main circuit-breaker, fuses and main
contactor functions are implemented by means of circuit-breakers
Motor connection
Inverter
Power connection
Rectifier
~
~
=
DC link
Main circuit-breaker 1)
Fuses 1)
Main contactor 1)
~
~
=
~
~
=
~
~
=
Line reactor Uk = 2 %
< 500 kW standard
> 500 kW only as option
( L23 ) !
Version A Version C
PE
PE
PE
PE
R1
R2
Brake chopper
Fig. 2-3 Wiring principle: versions A and C
IMPORTANT
The motor earth must be fed back directly to the cabinet unit.

11/03 Device Overview
SINAMICS G150
Operating Manual 2-7
2.5 Type Plate
Device designation
List of device
options
Month of manufacture
Year of manufacture
Fig. 2-4 Type plate for the cabinet unit
Date of Manufacture
The date of manufacture can be ascertained as follows:
Table 2-1 Year and month of manufacture
Letter /
number
Year of manufacture Letter /
number
Month of manufacture
R 2003 1 to 9 January to September
S 2004 O October
T 2005 N November
U 2006 D December

Device Overview 11/03
SINAMICS G150
2-8 Operating Manual
Type Plate Data (from Type Plate on Previous Page)
Table 2-2 Type plate data
Specification Value Explanation
Input 3AC
380 – 480 V
239 A
Three-phase connection
Rated input voltage
Rated input current
Output 3AC
0 – 480 V
210 A
Three-phase connection
Rated output voltage
Rated output current
Temperature range 0 -40 °C Ambient temperature range within which the cabinet unit can
operate under 100 % load
Degree of protection IP20 Degree of protection
Duty class I I: Duty class I to EN 60146-1-1 = 100 % (continuously)
(with the specified current values, the cabinet unit can operate
continuously under 100 % load)
Cooling method AF A: coolant: air
F: circulation method: forced cooling, drive unit (fan) in the
device
Weight Weight of the cabinet unit
Explanation of the Option Short Codes
Table 2-3 Explanation of the option codes
Version
A C
Input options
L00 Radio interference suppression filter, limit class A1 (TN, TT systems) •−
L13 Main contactor (for currents < 800 A) •−
L22 Without line reactor in power range P < 500 kW (available soon) ••
L23 Line reactor uk= 2 % for P > 500 kW ••
L26 Main circuit-breaker (incl. fuses/circuit-breakers) •−
Output options
L08 Output filter •−
Input and output options
M70 EMC shield bus ••
M75 PE busbar ••