Siemens SINAMICS S120 Technical Document

SINAMICS S120 Booksize power units
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Foreword
System Overview
1
Line Connection Booksize
2
Line Modules Booksize
3
Motor Modules Booksize
4
Motor Modules Booksize
Compact
5
Booksize DC Link
Components
6
Motor-Side Power
Components
7
Accessories
8
Cabinet Design and EMC
Booksize
9
Service and Support
Booksize
10
Appendix A
A
SINAMICS
S120
SINAMICS S120 Booksize power
units
Manual
(GH2), 06/2008
6SL3097-2AC00-0BP6

Safety Guidelines
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
with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.
CAUTION
without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.
NOTICE
indicates that an unintended result or situation can occur if the corresponding information is not taken into
account.
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 device/system may only be set up and used in conjunction with this documentation. Commissioning and
operation of a device/system may only be performed by qualified personnel. Within the context of the safety notes
in this documentation qualified persons are defined as persons who are authorized to commission, ground and
label devices, systems and circuits in accordance with established safety practices and standards.
Prescribed Usage
Note the following:
WARNING
This device may only be used for the applications described in the catalog or the technical description and only
in connection with devices or components from other manufacturers which have been approved or
recommended by Siemens. Correct, reliable operation of the product requires proper transport, storage,
positioning and assembly as well as careful operation and maintenance.
Trademarks
All names identified by ® are registered trademarks of the 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
Automation and Drives
Postfach 48 48
90327 NÜRNBERG
GERMANY
Order number: 6SL3097-2AC00-0BP6
Ⓟ 02/2008
Copyright © Siemens AG 2004,
11/2002.
Technical data subject to change

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Manual, (GH2), 06/2008, 6SL3097-2AC00-0BP6 5
Foreword
SINAMICS Documentation
The SINAMICS documentation is organized in 2 parts:
● General Documentation/Catalogs
● Manufacturer/Service Documentation
An overview of publications, which is updated on a monthly and also provides information
about the language versions available, can be found on the Internet at:
http://www.siemens.com/motioncontrol
Select the menu items "Support" → "Technical Documentation" → "Overview of Publications".
The Internet version of DOConCD (DOConWEB) is available under:
http://www.automation.siemens.com/doconweb
Information about training courses and FAQs (Frequently Asked Questions) can be found at
the following website:
http://www.siemens.com/motioncontrol under menu option "Support"
Usage phases
Table 1 Usage phase and the available documents/tools
Usage phase Tools
Orientation SINAMICS S Sales Documentation
Planning/configuration SIZER configuration tool
Decision/ordering SINAMICS S Catalogs
Installation/assembly •SINAMICS S120 Equipment Manual for Control Units and
Supplementary System Components
•SINAMICS S120 Equipment Manual Power Modules Booksize
•SINAMICS S120 Equipment Manual Power Modules Chassis
•SINAMICS S150 Operating Instructions
Commissioning •STARTER parameterization and commissioning tool
•SINAMICS S120 Getting Started
•SINAMICS S120 Commissioning Manual
•SINAMICS S120 CANopen Commissioning Manual
•SINAMICS S List Manual
•SINAMICS S150 Operating Instructions

Foreword
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6 Manual, (GH2), 06/2008, 6SL3097-2AC00-0BP6
Usage phase Tools
Usage/operation •SINAMICS S120 Commissioning Manual
•SINAMICS S List Manual
•SINAMICS S150 Operating Instructions
Maintenance/servicing •SINAMICS S120 Commissioning Manual
•SINAMICS S List Manual
•SINAMICS S150 Operating Instructions
Target group
This Manual addresses planners, installation technicians, design engineers.
Benefits
This manual provides information on the components and functions of devices so that the
target group is capable of installing, setting up, testing, operating, and troubleshooting the
devices safely and correctly.
Standard scope
This documentation only describes the functionality of the standard version. Extensions or
changes made by the machine tool manufacturer are documented by the machine tool
manufacturer.
Other functions not described in this documentation might be able to be executed in the drive
system. This does not, however, represent an obligation to supply such functions with a new
control or when servicing.
Further, for the sake of simplicity, this documentation does not contain all detailed
information about all types of the product and cannot cover every conceivable case of
installation, operation or maintenance.

Foreword
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Manual, (GH2), 06/2008, 6SL3097-2AC00-0BP6 7
Technical Support
If you have any questions, please get in touch with our Hotline:
Europe/Africa
Phone [phone] - 222
Fax [phone] - 223
Internet http://www.siemens.com/automation/support-request
America
Phone [phone]
Fax [phone]
E-mail mailto:[email protected]
Asia/Pacific
Phone [phone]
Fax [phone]
E-mail mailto:[e-mail]
Note
You will find telephone numbers for technical support in other countries on the Internet:
http://www.siemens.com/automation/service&support
Questions about the documentation
If you have any questions (suggestions, corrections) regarding this documentation, please
fax or e-mail us at:
Fax [phone]
E-mail mailto:[email protected]
A fax form is available in the appendix of this document.
Internet address for SINAMICS
http://www.siemens.com/sinamics

Foreword
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8 Manual, (GH2), 06/2008, 6SL3097-2AC00-0BP6
EC Declarations of Conformity
The EC Declaration of Conformity for the EMC Directive can be found/obtained:
● on the Internet:
http://support.automation.siemens.com
under the Product/Order No. 15257461
● with the responsible branch office of the A&D MC Business Division of Siemens AG.
The EC Declaration of Conformity for the Low Voltage Directive can be found/obtained
● on the Internet:
http://support.automation.siemens.com
under the Product/Order No. 22383669
Note
When operated in dry areas, SINAMICS S devices conform to the Low Voltage Directive
73/23/EEC or 2006/95/EEC.
Note
SINAMICS S devices comply with EMC Directive 89/336/EEC or 2004/108/EC in the
configuration specified in the associated EC Declaration of Conformity and when the EMC
installation guideline is implemented, Order No. 6FC 5297-AD30-0AP.
DANGER
Electrical, magnetic and electromagnetic fields (EMF) that occur during operation can pose
a danger to persons who are present in the direct vicinity of the product - especially
persons with pacemakers, implants, or similar devices.
The relevant directives and standards must be observed by the machine/plant operators
and persons present in the vicinity of the product. These are, for example, EMF Directive
2004/40/EEC and standards EN 12198-1 and -3 pertinent to the European Economic Area
(EEA), as well as accident prevention code BGV 11 and the associated rule BGR 11
"Electromagnetic fields" of the German employer's liability accident insurance assocation.
These state that a hazard analysis must drawn up for every workplace, from which
measures for reducing dangers and their impact on persons are derived and applied, and
exposure and danger zones are defined and observed.
The relevant safety notes in each chapter must be observed.

Foreword
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Manual, (GH2), 06/2008, 6SL3097-2AC00-0BP6 9
ESD information
CAUTION
Electrostatic sensitive devices (ESDs) are individual components, integrated circuits, or
boards that may be damaged by either electrostatic fields or electrostatic discharge.
Regulations for handling ESD components:
When handling components, make sure that personnel, workplaces, and packaging are
well earthed.
Personnel may only come into contact with electronic components, if
•They are grounded with an ESD wrist band, or
•They are in ESD areas with conductive flooring, ESD shoes or ESD grounding straps.
Electronic boards should only be touched if absolutely necessary. They must only be
handled on the front panel or, in the case of printed circuit boards, at the edge.
Electronic boards must not come into contact with plastics or items of clothing containing
synthetic fibers.
Boards must only be placed on conductive surfaces (work surfaces with ESD surface,
conductive ESD foam, ESD packing bag, ESD transport container).
Do not place boards near display units, monitors, or television sets (minimum distance from
screen: 10 cm).
Measurements must only be taken on boards when the measuring instrument is grounded
(via protective conductors, for example) or the measuring probe is briefly discharged before
measurements are taken with an isolated measuring device (for example, touching a bare
metal housing).
Safety information
DANGER
Commissioning must not start until you have ensured that the machine in which the
components described here are installed complies with Machine Directive 98/37/EEC.
Only appropriately qualified personnel may install, commission and maintain the SINAMICS
S devices.
The personnel must take into account the information provided in the technical customer
documentation for the product, and be familiar with and observe the specified danger and
warning notices.
Operational electrical equipment and motors have parts and components which are at
hazardous voltage levels that may cause serious injuries or death when touched.
All work on the electrical system must be carried out when the system has been
disconnected from the power supply.

Foreword
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10 Manual, (GH2), 06/2008, 6SL3097-2AC00-0BP6
DANGER
Correct and safe operation of SINAMICS S units assumes correct transportation in the
transportation packaging, correct long-term storage in the transport packaging, setup and
installation, as well as careful operation and maintenance.
The details in the catalogs and proposals also apply to the design of special equipment
versions.
In addition to the danger and warning information provided in the technical customer
documentation, the applicable national, local, and system-specific regulations and
requirements must be taken into account.
According to EN 61800-5-1 and UL 508 only safely isolated protective extra-low voltages of
the electronic modules may be connected to all connections and terminals.
DANGER
Using protection against direct contact via DVC A (PELV) is only permissible in areas with
equipotential bonding and in dry rooms indoors. If these conditions are not fulfilled, other
protective measures against electric shock (e.g. protection through protective impedances
or limited voltage, or use of protection class I and II) must be used.
DANGER
As part of routine tests, SINAMICS S components will undergo a voltage test in accordance
with EN 61800-5-1. Before the voltage test is performed on the electrical equipment of
machines to EN 60204-1, Section 19.4, all connections of SINAMICS units must be
disconnected/unplugged to prevent them from being damaged.
Motors should be connected-up corresponding to the circuit diagram supplied with the
motor (refer to the connection examples of Motor Modules). They must not be connected
directly to the three-phase supply because this will damage them.
WARNING
Operating the equipment in the immediate vicinity (< 1.8 m) of mobile telephones with a
transmitter power of > 1 W may lead to incorrect operation.

Foreword
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Manual, (GH2), 06/2008, 6SL3097-2AC00-0BP6 11
Explanation of symbols
The symbols are in accordance with IEC 617-2.
Table 2 Symbols
Symbol Description
Protective earth (PE)
Ground (e.g. M 24 V)
Functional ground (e.g. shield)
Equipotential bonding

Foreword
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12 Manual, (GH2), 06/2008, 6SL3097-2AC00-0BP6
Residual risks of power drive systems
When carrying out a risk assessment of the machine in accordance with the EU Machinery
Directive, the machine manufacturer must consider the following residual risks associated
with the control and drive components of a power drive system (PDS).
1. Unintentional movements of driven machine components during commissioning,
operation, maintenance, and repairs caused by, for example:
– Hardware defects and/or software errors in the sensors, controllers, actuators, and
connection technology
– Response times of the controller and drive
– Operating and/or ambient conditions not within the scope of the specification
– Parameterization, programming, cabling, and installation errors
– Use of radio devices/cellular phones in the immediate vicinity of the controller
– External influences/damage
2. Exceptional temperatures as well as emissions of light, noise, particles, or gas caused by,
for example:
– Component malfunctions
– Software errors
– Operating and/or ambient conditions not within the scope of the specification
– External influences/damage
3. Hazardous shock voltages caused by, for example:
– Component malfunctions
– Influence of electrostatic charging
– Induction of voltages in moving motors
– Operating and/or ambient conditions not within the scope of the specification
– Condensation/conductive contamination
– External influences/damage
4. Operational electrical, magnetic, and electromagnetic fields that can pose a risk to people
with a pacemaker and/or implants or metallic objects if they are too close.
5. Release of environmentally hazardous materials and emissions during improper
operation and/or improper disposal of components.
For more information about residual risks of the power drive system components, see the
relevant chapters in the technical user documentation.

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Manual, (GH2), 06/2008, 6SL3097-2AC00-0BP6 13
Table of Contents
Foreword ................................................................................................................................................... 5
1 System Overview..................................................................................................................................... 23
1.1 Field of application .......................................................................................................................23
1.2 Versions .......................................................................................................................................24
1.3 Platform concept and Totally Integrated Automation...................................................................25
1.4 Introduction ..................................................................................................................................26
1.5 SINAMICS S120 components......................................................................................................29
1.6 Power sections.............................................................................................................................30
1.7 System data .................................................................................................................................30
1.8 Standards.....................................................................................................................................32
2 Line Connection Booksize ....................................................................................................................... 35
2.1 Introduction ..................................................................................................................................35
2.2 Overview: line filters.....................................................................................................................37
2.3 Combining line reactors and line filters........................................................................................39
2.4 Basic Line Filter for Active Line Modules with line reactor ..........................................................41
2.4.1 Description ...................................................................................................................................41
2.4.2 Safety information ........................................................................................................................42
2.4.3 Interface description.....................................................................................................................43
2.4.3.1 Overview ......................................................................................................................................43
2.4.3.2 Line supply/load connection.........................................................................................................44
2.4.4 Dimension drawing ......................................................................................................................45
2.4.5 Technical data..............................................................................................................................46
2.5 Basic Line Filter for Active Line Modules with Active Interface Module.......................................47
2.5.1 Description ...................................................................................................................................47
2.5.2 Safety information ........................................................................................................................47
2.5.3 Interface description.....................................................................................................................49
2.5.3.1 Overview ......................................................................................................................................49
2.5.3.2 Line/power connection.................................................................................................................51
2.5.4 Dimension drawing ......................................................................................................................52
2.5.5 Technical data..............................................................................................................................54
2.6 Wideband Line Filter for Active Line Modules .............................................................................55
2.6.1 Description ...................................................................................................................................55
2.6.2 Safety information ........................................................................................................................55
2.6.3 Interface description.....................................................................................................................57
2.6.3.1 Line/power connection.................................................................................................................58
2.6.4 Dimension drawings.....................................................................................................................59
2.6.5 Technical data..............................................................................................................................64

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2.7 Basic Line Filter for Basic Line Modules ..................................................................................... 65
2.7.1 Description .................................................................................................................................. 65
2.7.2 Safety information ....................................................................................................................... 65
2.7.3 Interface description.................................................................................................................... 67
2.7.3.1 Overview ..................................................................................................................................... 67
2.7.3.2 Line/power connection ................................................................................................................ 68
2.7.4 Dimension drawing...................................................................................................................... 69
2.7.5 Technical data............................................................................................................................. 71
2.8 Basic Line Filter for Smart Line Modules .................................................................................... 72
2.8.1 Description .................................................................................................................................. 72
2.8.2 Safety information ....................................................................................................................... 72
2.8.3 Interface description.................................................................................................................... 74
2.8.3.1 Overview ..................................................................................................................................... 74
2.8.3.2 Line/power connection ................................................................................................................ 75
2.8.4 Dimension drawings.................................................................................................................... 76
2.8.5 Technical data............................................................................................................................. 78
2.9 Active Interface Modules internal air cooling .............................................................................. 79
2.9.1 Description .................................................................................................................................. 79
2.9.2 Safety information ....................................................................................................................... 79
2.9.3 Interface description.................................................................................................................... 80
2.9.3.1 Overview ..................................................................................................................................... 80
2.9.3.2 Connection example ................................................................................................................... 84
2.9.3.3 Electronics power supply X124................................................................................................... 85
2.9.3.4 Line/power connection ................................................................................................................ 85
2.9.3.5 X121 temperature sensor and fan control................................................................................... 86
2.9.4 Dimension drawings.................................................................................................................... 87
2.9.5 Installation ................................................................................................................................... 92
2.9.6 Technical data............................................................................................................................. 99
2.10 Line reactors for Active Line Modules....................................................................................... 100
2.10.1 Description ................................................................................................................................ 100
2.10.2 Safety information ..................................................................................................................... 100
2.10.3 Connection description.............................................................................................................. 101
2.10.3.1 Line/power connection .............................................................................................................. 101
2.10.4 Dimension drawings.................................................................................................................. 102
2.10.5 Technical data........................................................................................................................... 103
2.11 Line reactors for Smart Line Modules ....................................................................................... 104
2.11.1 Description ................................................................................................................................ 104
2.11.2 Safety information ..................................................................................................................... 104
2.11.3 Connection description.............................................................................................................. 105
2.11.3.1 Line/power connection .............................................................................................................. 105
2.11.4 Dimension drawings.................................................................................................................. 106
2.11.5 Technical data........................................................................................................................... 109
2.12 Line reactors for Basic Line Modules........................................................................................ 110
2.12.1 Description ................................................................................................................................ 110
2.12.2 Safety information ..................................................................................................................... 110
2.12.3 Connection description.............................................................................................................. 111
2.12.3.1 Overview ................................................................................................................................... 111
2.12.3.2 Line/power connection .............................................................................................................. 112
2.12.4 Dimension drawings.................................................................................................................. 113
2.12.5 Technical data........................................................................................................................... 115

Table of Contents
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2.13 Line connection variants ............................................................................................................116
2.13.1 Ways of connecting the line supply ...........................................................................................116
2.13.2 Operating line connection components on the line supply ........................................................118
2.13.3 Operating line connection components via a matching transformer..........................................119
2.13.3.1 Safety information ......................................................................................................................119
2.13.3.2 Line supply connection conditions for Line Modules .................................................................119
2.13.3.3 Operation of the line connection components via an autotransformer ......................................126
2.13.3.4 Assignment of autotransformers to Active Line Modules ..........................................................128
2.13.3.5 Assignment of autotransformers to Smart Line Modules...........................................................130
2.13.3.6 Assignment of autotransformers to Basic Line Modules ...........................................................132
2.13.3.7 Operating line connection components via an isolating transformer.........................................134
2.13.3.8 Assignment of isolating transformers to Active Line Modules ...................................................136
2.13.3.9 Assignment of isolating transformers to Smart Line Modules ...................................................137
2.13.3.10 Assignment of isolating transformers to Basic Line Modules ....................................................138
2.13.3.11 Technical specifications of the transformers..............................................................................139
2.13.3.12 Dimension drawings of the transformers ...................................................................................140
2.13.4 Line connection via a residual-current circuit-breaker ...............................................................144
3 Line Modules Booksize.......................................................................................................................... 147
3.1 Introduction ................................................................................................................................147
3.2 Active Line Modules with internal air cooling.............................................................................151
3.2.1 Description .................................................................................................................................151
3.2.2 Safety information ......................................................................................................................151
3.2.3 Interface description...................................................................................................................154
3.2.3.1 Overview ....................................................................................................................................154
3.2.3.2 Connection example ..................................................................................................................155
3.2.3.3 X1 line connection......................................................................................................................156
3.2.3.4 X200-X202 DRIVE-CLiQ interfaces...........................................................................................157
3.2.3.5 EP terminals X21 .......................................................................................................................158
3.2.3.6 X24 24 V terminal adapter .........................................................................................................159
3.2.3.7 Description of the LEDs on the Active Line Module ..................................................................160
3.2.4 Dimension drawing ....................................................................................................................161
3.2.5 Installation..................................................................................................................................164
3.2.6 Electrical connection ..................................................................................................................166
3.2.7 Technical data............................................................................................................................167
3.3 Active Line Modules with external air cooling............................................................................174
3.3.1 Description .................................................................................................................................174
3.3.2 Safety information ......................................................................................................................174
3.3.3 Interface description...................................................................................................................177
3.3.3.1 Overview ....................................................................................................................................177
3.3.3.2 Connection example ..................................................................................................................178
3.3.3.3 Line connection..........................................................................................................................179
3.3.3.4 X200-X202 DRIVE-CLiQ interfaces...........................................................................................180
3.3.3.5 EP terminals X21 .......................................................................................................................181
3.3.3.6 X24 24 V terminal adapter .........................................................................................................182
3.3.3.7 Meaning of the LEDs on the Active Line Module.......................................................................183
3.3.4 Dimension drawings...................................................................................................................184
3.3.5 Installation..................................................................................................................................186
3.3.6 Electrical connection ..................................................................................................................193
3.3.7 Technical data............................................................................................................................194

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3.4 Basic Line Modules with internal air cooling ............................................................................. 201
3.4.1 Description ................................................................................................................................ 201
3.4.2 Safety information ..................................................................................................................... 201
3.4.3 Interface description.................................................................................................................. 204
3.4.3.1 Overview ................................................................................................................................... 204
3.4.3.2 Connection example ................................................................................................................. 207
3.4.3.3 X1 line connection..................................................................................................................... 209
3.4.3.4 X24 24 V terminal adapter ........................................................................................................ 210
3.4.3.5 X200-X202 DRIVE-CLiQ interfaces .......................................................................................... 211
3.4.3.6 X2 braking resistor connection.................................................................................................. 212
3.4.3.7 X21 EP terminals ...................................................................................................................... 213
3.4.3.8 Meaning of the LEDs on the Basic Line Module....................................................................... 214
3.4.4 Dimension drawings.................................................................................................................. 215
3.4.5 Mounting.................................................................................................................................... 218
3.4.6 Electrical connection ................................................................................................................. 223
3.4.7 Technical data........................................................................................................................... 224
3.4.8 Braking resistors for Basic Line Modules.................................................................................. 230
3.4.9 Basic Line Modules 100 kW in combination with MASTERDRIVES braking module............... 234
3.4.9.1 Description ................................................................................................................................ 234
3.4.9.2 Safety information ..................................................................................................................... 235
3.4.9.3 Interface description.................................................................................................................. 237
3.4.9.4 Dimension drawing.................................................................................................................... 239
3.5 Smart Line Modules (5 kW und 10 kW) with internal air cooling .............................................. 241
3.5.1 Description ................................................................................................................................ 241
3.5.2 Safety information ..................................................................................................................... 241
3.5.3 Interface description.................................................................................................................. 244
3.5.3.1 Overview ................................................................................................................................... 244
3.5.3.2 Connection example ................................................................................................................. 245
3.5.3.3 X1 line connection..................................................................................................................... 246
3.5.3.4 X21 terminals: Smart Line Module............................................................................................ 246
3.5.3.5 X22 terminals: Smart Line Module............................................................................................ 247
3.5.3.6 X24 24 V terminal adapter ........................................................................................................ 248
3.5.3.7 Meaning of the LEDs on the Smart Line Module ...................................................................... 248
3.5.4 Dimension drawing.................................................................................................................... 249
3.5.5 Installation ................................................................................................................................. 250
3.5.6 Electrical connection ................................................................................................................. 251
3.5.7 Technical data........................................................................................................................... 252
3.6 Smart Line Modules (16 kW und 36 kW) with internal air cooling ............................................ 257
3.6.1 Description ................................................................................................................................ 257
3.6.2 Safety information ..................................................................................................................... 257
3.6.3 Interface description.................................................................................................................. 260
3.6.3.1 Overview ................................................................................................................................... 260
3.6.3.2 Connection example ................................................................................................................. 262
3.6.3.3 X1 line connection..................................................................................................................... 263
3.6.3.4 X200-X202 DRIVE-CLiQ interfaces .......................................................................................... 264
3.6.3.5 X21 EP terminals ...................................................................................................................... 265
3.6.3.6 X24 24 V terminal adapter ........................................................................................................ 266
3.6.3.7 Meaning of the LEDs on the Smart Line Module ...................................................................... 267
3.6.4 Dimension drawings.................................................................................................................. 268
3.6.5 Installation ................................................................................................................................. 270
3.6.6 Electrical connection ................................................................................................................. 271
3.6.7 Technical data........................................................................................................................... 272

Table of Contents
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3.7 Smart Line Modules Booksize Compact....................................................................................277
3.7.1 Description .................................................................................................................................277
3.7.2 Safety information ......................................................................................................................277
3.7.3 Interface description...................................................................................................................280
3.7.3.1 Overview ....................................................................................................................................280
3.7.3.2 Connection example ..................................................................................................................281
3.7.3.3 X1 line connection......................................................................................................................282
3.7.3.4 X200-X202 DRIVE-CLiQ interfaces...........................................................................................282
3.7.3.5 X21 EP terminals .......................................................................................................................283
3.7.3.6 X24 24 V terminal adapter .........................................................................................................284
3.7.3.7 Meaning of the LEDs on the Smart Line Module.......................................................................285
3.7.4 Dimension drawing ....................................................................................................................286
3.7.5 Assembly....................................................................................................................................287
3.7.6 Electrical connection ..................................................................................................................289
3.7.7 Technical data............................................................................................................................290
3.8 Smart Line Modules (5 kW und 10 kW) with external air cooling ..............................................294
3.8.1 Description .................................................................................................................................294
3.8.2 Safety information ......................................................................................................................294
3.8.3 Interface description...................................................................................................................297
3.8.3.1 Overview ....................................................................................................................................297
3.8.3.2 Connection example ..................................................................................................................298
3.8.3.3 X1 line connection......................................................................................................................299
3.8.3.4 X21 terminals: Smart Line Module.............................................................................................300
3.8.3.5 X22 terminals: Smart Line Module.............................................................................................301
3.8.3.6 X24 24 V terminal adapter .........................................................................................................302
3.8.3.7 Meaning of the LEDs on the Smart Line Module.......................................................................302
3.8.4 Dimension drawing ....................................................................................................................303
3.8.5 Installation..................................................................................................................................304
3.8.6 Electrical connection ..................................................................................................................310
3.8.7 Technical data............................................................................................................................311
4 Motor Modules Booksize ....................................................................................................................... 317
4.1 Introduction ................................................................................................................................317
4.2 Motor Modules with internal air cooling .....................................................................................320
4.2.1 Description .................................................................................................................................320
4.2.2 Safety information ......................................................................................................................320
4.2.3 Interface description...................................................................................................................323
4.2.3.1 Overview ....................................................................................................................................323
4.2.3.2 Connection examples ................................................................................................................324
4.2.3.3 Motor/brake connection .............................................................................................................325
4.2.3.4 X21/X22 EP terminals/temperature sensor Motor Module ........................................................327
4.2.3.5 X200-X203 DRIVE-CLiQ interface.............................................................................................328
4.2.3.6 Meaning of the LEDs on the Motor Module ...............................................................................329
4.2.4 Dimension drawings...................................................................................................................330
4.2.5 Installation..................................................................................................................................335
4.2.6 Electrical connection ..................................................................................................................336
4.2.7 Technical data............................................................................................................................337
4.3 Motor Module with external air cooling ......................................................................................344
4.3.1 Description .................................................................................................................................344
4.3.2 Safety information ......................................................................................................................344
4.3.3 Interface description...................................................................................................................348
4.3.3.1 Overview ....................................................................................................................................348
4.3.3.2 Connection examples ................................................................................................................349

Table of Contents
Booksize power units
18 Manual, (GH2), 06/2008, 6SL3097-2AC00-0BP6
4.3.3.3 Motor/brake connection............................................................................................................. 350
4.3.3.4 X21/X22 EP terminals/temperature sensor Motor Module ....................................................... 352
4.3.3.5 X200-X203 DRIVE-CLiQ interface............................................................................................ 352
4.3.3.6 Meaning of the LEDs on the Motor Module .............................................................................. 353
4.3.4 Dimension drawing.................................................................................................................... 354
4.3.5 Installation ................................................................................................................................. 359
4.3.6 Electrical connection ................................................................................................................. 366
4.3.7 Technical data........................................................................................................................... 367
5 Motor Modules Booksize Compact ........................................................................................................ 375
5.1 Description ................................................................................................................................ 375
5.2 Safety information ..................................................................................................................... 375
5.3 Interface description.................................................................................................................. 378
5.3.1 Overview ................................................................................................................................... 378
5.3.2 Connection example ................................................................................................................. 381
5.3.3 X1 motor connection ................................................................................................................. 382
5.3.4 Motor brake connection............................................................................................................. 383
5.3.5 X21/X22 EP terminals/temperature sensor Motor Module ....................................................... 384
5.3.6 X200-X203 DRIVE-CLiQ interface............................................................................................ 385
5.3.7 Meaning of the LEDs on the Motor Module .............................................................................. 386
5.4 Dimension drawings.................................................................................................................. 387
5.5 Assembly................................................................................................................................... 390
5.6 Electrical connection ................................................................................................................. 393
5.7 Technical data........................................................................................................................... 394
6 Booksize DC Link Components ............................................................................................................. 401
6.1 Braking Modules ....................................................................................................................... 401
6.1.1 Description ................................................................................................................................ 401
6.1.2 Safety information ..................................................................................................................... 402
6.1.3 Interface description.................................................................................................................. 404
6.1.3.1 Overview ................................................................................................................................... 404
6.1.3.2 Connection example ................................................................................................................. 405
6.1.3.3 Braking resistor connection X1 ................................................................................................. 405
6.1.3.4 X21 digital inputs/outputs.......................................................................................................... 406
6.1.3.5 Meaning of the LEDs on the Braking Module ........................................................................... 407
6.1.4 Dimension drawing.................................................................................................................... 408
6.1.5 Mounting.................................................................................................................................... 409
6.1.6 Technical data........................................................................................................................... 410
6.1.7 Braking resistors for Braking Module........................................................................................ 411
6.2 Capacitor Module ...................................................................................................................... 414
6.2.1 Description ................................................................................................................................ 414
6.2.2 Safety information ..................................................................................................................... 414
6.2.3 Interface description.................................................................................................................. 416
6.2.3.1 Overview ................................................................................................................................... 416
6.2.4 Dimension drawing.................................................................................................................... 417
6.2.5 Installation ................................................................................................................................. 418
6.2.6 Technical data........................................................................................................................... 419
6.3 Control Supply Module.............................................................................................................. 420
6.3.1 Description ................................................................................................................................ 420
6.3.2 Safety information ..................................................................................................................... 420
6.3.3 Interface description.................................................................................................................. 422

Table of Contents
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Manual, (GH2), 06/2008, 6SL3097-2AC00-0BP6 19
6.3.3.1 Overview ....................................................................................................................................422
6.3.3.2 Connection example ..................................................................................................................423
6.3.3.3 Meaning of the LEDs on the Control Supply Module.................................................................424
6.3.4 Dimension drawing ....................................................................................................................425
6.3.5 Technical data............................................................................................................................426
6.4 Voltage Clamping Module..........................................................................................................427
6.4.1 Description .................................................................................................................................427
6.4.2 Safety information ......................................................................................................................428
6.4.3 Interface description...................................................................................................................430
6.4.3.1 Overview ....................................................................................................................................430
6.4.3.2 X1 functional ground ..................................................................................................................431
6.4.4 Dimension drawing ....................................................................................................................432
6.4.5 Mounting ....................................................................................................................................433
6.4.6 Technical data............................................................................................................................433
7 Motor-Side Power Components............................................................................................................. 435
7.1 Motor reactors............................................................................................................................435
7.1.1 Description .................................................................................................................................435
7.1.2 Safety information ......................................................................................................................436
7.1.3 Dimension drawings...................................................................................................................437
7.1.4 Technical data............................................................................................................................441
8 Accessories ........................................................................................................................................... 443
8.1 Shield connecting plates ............................................................................................................443
8.1.1 Description .................................................................................................................................443
8.1.2 Overview ....................................................................................................................................444
8.1.3 Dimension drawings...................................................................................................................446
8.1.4 Installation..................................................................................................................................454
8.1.5 Electrical connection ..................................................................................................................457
8.2 DC link rectifier adapter for Booksize format .............................................................................459
8.2.1 Description .................................................................................................................................459
8.2.2 Safety information ......................................................................................................................459
8.2.3 Interface description...................................................................................................................461
8.2.3.1 Overview ....................................................................................................................................461
8.2.3.2 DC link connection .....................................................................................................................462
8.2.4 Dimension drawings...................................................................................................................463
8.2.5 Installation..................................................................................................................................465
8.2.6 Electrical connection ..................................................................................................................469
8.3 DC link adapter ..........................................................................................................................470
8.3.1 Description .................................................................................................................................470
8.3.2 Safety information ......................................................................................................................470
8.3.3 Interface description...................................................................................................................472
8.3.3.1 Overview ....................................................................................................................................472
8.3.3.2 DC link connection .....................................................................................................................473
8.3.4 Dimension drawing ....................................................................................................................474
8.3.5 Installation..................................................................................................................................475
8.3.6 Electrical connection ..................................................................................................................477
8.4 Reinforced DC-link busbars .......................................................................................................478
8.4.1 Description .................................................................................................................................478
8.4.2 Safety information ......................................................................................................................479
8.4.3 Dimension drawings...................................................................................................................480
8.4.4 Removing the DC link busbars ..................................................................................................482
8.4.5 Mounting the reinforced DC link busbars...................................................................................482

Table of Contents
Booksize power units
20 Manual, (GH2), 06/2008, 6SL3097-2AC00-0BP6
8.5 DRIVE-CLiQ cabinet gland ....................................................................................................... 483
8.5.1 Description ................................................................................................................................ 483
8.5.2 Safety information ..................................................................................................................... 483
8.5.3 Interface description.................................................................................................................. 484
8.5.3.1 Overview ................................................................................................................................... 484
8.5.4 Dimension drawing.................................................................................................................... 485
8.5.5 Mounting.................................................................................................................................... 487
8.5.6 Technical data........................................................................................................................... 488
8.6 DRIVE-CLiQ coupling ............................................................................................................... 489
8.6.1 Description ................................................................................................................................ 489
8.6.2 Safety information ..................................................................................................................... 489
8.6.3 Interface description.................................................................................................................. 489
8.6.3.1 Overview ................................................................................................................................... 489
8.6.4 Dimension drawing.................................................................................................................... 490
8.6.5 Installation ................................................................................................................................. 491
8.6.6 Technical data........................................................................................................................... 491
9 Cabinet Design and EMC Booksize....................................................................................................... 493
9.1 Information ................................................................................................................................ 493
9.1.1 General information................................................................................................................... 493
9.1.2 Safety information ..................................................................................................................... 494
9.1.3 Directives................................................................................................................................... 495
9.2 Selecting devices required to operate SINAMICS .................................................................... 496
9.2.1 General...................................................................................................................................... 496
9.2.2 Information about line isolating devices .................................................................................... 496
9.2.3 Overcurrent protection by means of line fuses or circuit-breakers ........................................... 497
9.2.4 Line filter.................................................................................................................................... 499
9.2.5 Line contactors.......................................................................................................................... 500
9.3 24 V DC supply voltage............................................................................................................. 501
9.3.1 General information................................................................................................................... 501
9.3.2 Selecting power supply units..................................................................................................... 502
9.3.3 Typical 24 V current consumption of the components.............................................................. 503
9.3.4 Overcurrent protection .............................................................................................................. 505
9.4 Arrangement of components and equipment............................................................................ 509
9.4.1 General information................................................................................................................... 509
9.4.2 Current carrying capacity of the DC link busbar ....................................................................... 509
9.4.3 Drive line-up .............................................................................................................................. 512
9.5 Information about electromagnetic compatibility (EMC) and cable routing .............................. 518
9.5.1 General information................................................................................................................... 518
9.5.2 Cable shielding and routing....................................................................................................... 518
9.5.3 Equipotential bonding................................................................................................................ 522
9.6 Connection systems.................................................................................................................. 524
9.6.1 Spring-loaded terminals/screw terminals .................................................................................. 524
9.6.2 Connectable cable cross-sections ............................................................................................ 526
9.6.3 Motor connector ........................................................................................................................ 529
9.6.4 Power connector (X1/X2).......................................................................................................... 531
9.6.5 24 V terminal adapter................................................................................................................ 534
9.7 Cooling ...................................................................................................................................... 535
9.7.1 General...................................................................................................................................... 535
9.7.2 Information about ventilation..................................................................................................... 541
9.7.3 Power loss of components in rated operation........................................................................... 543
9.7.4 Dimensioning climate control equipment .................................................................................. 548