Siemens SINAMICS S120 User manual

Booksize Power Units
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SINAMICS
S120
Booksize Power Units
Manual
(GH2), 04/2014
6SL3097
-4AC00-0BP6
Preface
Fundamental safety
instructions
1
System overview
2
Line connection and line-side
power components
3
Line Modules Booksize
4
Line Modules Booksize
Compact
5
Motor Modules Booksize
6
Motor Modules Booksize
Compact
7
DC link components
8
Braking resistors
9
Motor-side power
components
10
Accessories
11
Cabinet design and EMC
Booksize
12
Cooling circuit and coolant
properties
13
Service and Support
Booksize
14
Appendix
A

Siemens AG
Industry Sector
Postfach 48 48
90026 NÜRNBERG
GERMANY
Order number: 6SL3097-4AC00-0BP6
Ⓟ
04/2014 Subject to change
Copyright © Siemens AG 2004 - 2014.
All rights reserved
Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
indicates that minor personal injury can result if proper precautions are not taken.
NOTICE
indicates that property damage can result if proper precautions are not taken.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
Qualified Personnel
The product/system described in this documentation may be operated only by
personnel qualified
for the specific
task in accordance with the relevant documentation, in particular its warning notices and safety instructions.
Qualified personnel are those who, based on their training and experience, are capable of identifying risks and
avoiding potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended
or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be complied with. The information in the relevant documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication
may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.

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Manual, (GH2), 04/2014, 6SL3097-4AC00-0BP6 5
Preface
Preface SINAMICS general
SINAMICS documentation
The SINAMICS documentation is organized in the following categories:
●General documentation/catalogs
●User documentation
●Manufacturer/service documentation
Additional information
The following link provides information on the topics:
●Ordering documentation/overview of documentation
●Additional links to download documents
●Using documentation online (find and search in manuals/information)
http://www.siemens.com/motioncontrol/docu
Please send any questions about the technical documentation (e.g. suggestions for
improvement, corrections) to the following e-mail address:
[e-mail]
My Documentation Manager
Under the following link there is information on how to create your own individual
documentation based on Siemens' content, and adapt it for your own machine
documentation:
http://www.siemens.com/mdm
Training
Information about SITRAIN (Siemens training on products, systems and solutions for
automation and drives) is available under the following link:
http://www.siemens.com/sitrain
FAQs
You can find Frequently Asked Questions on the Service&Support pages under
Product
Support
.
http://support.automation.siemens.com

Preface
Booksize Power Units
6Manual, (GH2), 04/2014, 6SL3097-4AC00-0BP6
SINAMICS
You can find information on SINAMICS at:
http://www.siemens.com/sinamics.
Usage phases and their documents/tools (as an example)
Table 1 Usage phases and the available documents/tools
Usage phase
Document/tool
Orientation
SINAMICS S Sales Documentation
Planning/configuration •SIZER Engineering Tool
•Configuration Manuals, Motors
Deciding/ordering SINAMICS S120 catalogs
•SIMOTION, SINAMICS S120 and Motors for Production
Machines (Catalog PM 21)
•SINAMICS and Motors for Single-axis Drives (Catalog D 31)
•SINUMERIK & SINAMICS
Equipment for Machine Tools (Catalog NC 61)
•SINUMERIK 840D sl Type 1B
Equipment for Machine Tools (Catalog NC 62)
Installation/assembly •SINAMICS S120 Equipment Manual for Control Units and
Additional System Components
•SINAMICS S120 Equipment Manual for Booksize Power
Units
•SINAMICS S120 Equipment Manual for Chassis Power Units
•SINAMICS S120 Equipment Manual for AC Drives
•SINAMICS S120M Equipment Manual Distributed Drive
Technology
•SINAMICS HLA System Manual Hydraulic Drive
Commissioning •STARTER Commissioning Tool
•SINAMICS S120 Getting Started
•SINAMICS S120 Commissioning Manual
•SINAMICS S120 CANopen Commissioning Manual
•SINAMICS S120 Function Manual
•SINAMICS S120 Safety Integrated Function Manual
•SINAMICS S120/S150 List Manual
•SINAMICS HLA System Manual Hydraulic Drive
Usage/operation •SINAMICS S120 Commissioning Manual
•SINAMICS S120/S150 List Manual
•SINAMICS HLA System Manual Hydraulic Drive

Preface
Booksize Power Units
Manual, (GH2), 04/2014, 6SL3097-4AC00-0BP6 7
Usage phase
Document/tool
Maintenance/servicing •SINAMICS S120 Commissioning Manual
•SINAMICS S120/S150 List Manual
References •SINAMICS S120/S150 List Manual
Target group
This documentation is intended for machine manufacturers, commissioning engineers, and
service personnel who use the SINAMICS drive system.
Benefits
This manual describes all the information, procedures and operational instructions required
for commissioning and servicing SINAMICS S120.
Standard scope
The scope of the functionality described in this document can differ from that of the drive
system that is actually supplied.
●It may be possible for other functions not described in this documentation to be executed
in the drive system. However, no claim can be made regarding the availability of these
functions when the equipment is first supplied or in the event of servicing.
●Functions that are not available in a particular product version of the drive system may be
described in the documentation. The functionality of the supplied drive system should
only be taken from the ordering documentation.
●Extensions or changes made by the machine manufacturer must be documented by the
machine manufacturer.
For reasons of clarity, this documentation does not contain all of the detailed information on
all of the product types, and cannot take into consideration every conceivable type of
installation, operation and service/maintenance.
Technical Support
Country-specific telephone numbers for technical support are provided on the Internet at
Contact
:
http://www.siemens.com/automation/service&support
EC Declaration of Conformity
The EC Declarations of Conformity for the machinery directive can be found on the Internet
at:
http://support.automation.siemens.com/WW/view/de/21901735/67385845
Alternatively, you can contact the Siemens office in your region in order to obtain the EC
Declaration of Conformity.

Preface
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8Manual, (GH2), 04/2014, 6SL3097-4AC00-0BP6
Note
Complying with the low-voltage directive
When operated in dry areas, SINAMICS S units conform to Low
-Voltage Directive
2006/95/EC.
Note
Fulfilling the EMC Directive
SINAMICS S units fulfill EMC Directive 2004/108/EC in the configuration
specified in the
associated EC Declaration of Conformity for EMC and when the EMC installation guideline
provided in the Configuration Manual with Order No. 6FC5297
-0AD30-0AP3 is implemented.
Note
Ensuring reliable operation
The manual describes a desi
red state. The required reliable operation and the compliance
with EMC limit values can only be ensured when this is maintained.
EMC limit values in South Korea
The EMC limit values to be complied with for South Korea correspond to the limit values of
the EMC product standard for variable-speed electric drives EN 61800-3, Category C2 or
limit value class A, Group 1 according to EN 55011. By applying suitable supplementary
measures, the limit values according to Category C2 or according to limit value class A,
Group 1, are maintained. Further, additional measures may be required, for instance, using
an additional radio interference suppression filter (EMC filter).
The measures for EMC-compliant design of the system are described in detail in this manual
respectively in the EMC Installation Guideline Configuration Manual.
The final statement regarding compliance with the standard is given by the respective label
attached to the individual unit.
Spare parts
Spare parts are available on the Internet at:
http://support.automation.siemens.com/WW/view/de/16612315

Preface
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Manual, (GH2), 04/2014, 6SL3097-4AC00-0BP6 9
Test certificates
Test certificates for functional safety functions ("Safety Integrated") can be found at:
http://support.automation.siemens.com
An up-to-date list of currently certified components is also available on request from your
local Siemens office. If you have any questions relating to certifications that have not yet
been completed, please ask your Siemens contact.
Grounding symbols
Table 2 Symbols
Symbol
Meaning
Connection for protective conductor (PE)
Ground (e.g. M 24 V)
Connection for function equipotential bonding

Preface
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Manual, (GH2), 04/2014, 6SL3097-4AC00-0BP6 11
Table of contents
Preface ................................................................................................................................................... 5
1 Fundamental safety instructions ............................................................................................................ 25
1.1 General safety instructions ..........................................................................................................25
1.2 Safety instructions for electromagnetic fields (EMF) ...................................................................28
1.3 Handling electrostatic sensitive devices (ESD) ...........................................................................29
1.4 Industrial security .........................................................................................................................29
1.5 Residual risks of power drive systems.........................................................................................30
2 System overview................................................................................................................................... 33
2.1 Field of application .......................................................................................................................33
2.2 Platform Concept and Totally Integrated Automation..................................................................34
2.3 Introduction ..................................................................................................................................36
2.4 SINAMICS S120 components......................................................................................................38
2.4.1 Overview of Line Modules............................................................................................................40
2.4.2 Overview of Motor Modules .........................................................................................................43
2.5 System data .................................................................................................................................45
2.6 Derating as a function of the installation altitude and ambient temperature................................47
3 Line connection and line-side power components.................................................................................. 49
3.1 Introduction ..................................................................................................................................49
3.2 Information on the disconnector unit............................................................................................50
3.3 Overcurrent protection by means of line fuses and circuit breakers............................................51
3.4 Line supply connection via residual-current devices ...................................................................53
3.4.1 Residual-current operated circuit breakers (RCD).......................................................................53
3.4.2 Residual-current monitors (RCM) ................................................................................................55
3.5 Overvoltage protection.................................................................................................................57
3.6 Line contactors.............................................................................................................................57
3.7 Line filters.....................................................................................................................................58
3.7.1 Safety instructions for line filters ..................................................................................................58
3.7.2 Overview of line filters..................................................................................................................60
3.7.3 Basic Line Filters for Active Line Modules ...................................................................................62
3.7.3.1 Description ...................................................................................................................................62
3.7.3.2 Interface description.....................................................................................................................63
3.7.3.3 Dimension drawings.....................................................................................................................64
3.7.3.4 Technical data..............................................................................................................................67
3.7.4 Wideband Line Filter for Active Line Modules .............................................................................68
3.7.4.1 Description ...................................................................................................................................68
3.7.4.2 Interface description.....................................................................................................................69

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3.7.4.3 Dimension drawings.................................................................................................................... 71
3.7.4.4 Technical data............................................................................................................................. 75
3.7.5 Basic Line Filter for Basic Line Modules ..................................................................................... 76
3.7.5.1 Description .................................................................................................................................. 76
3.7.5.2 Interface description.................................................................................................................... 77
3.7.5.3 Dimension drawings.................................................................................................................... 78
3.7.5.4 Technical specifications .............................................................................................................. 80
3.7.6 Basic Line Filter for Smart Line Modules .................................................................................... 81
3.7.6.1 Description .................................................................................................................................. 81
3.7.6.2 Interface description.................................................................................................................... 82
3.7.6.3 Dimension drawings.................................................................................................................... 83
3.7.6.4 Technical Specifications.............................................................................................................. 85
3.8 Line reactors ............................................................................................................................... 86
3.8.1 Safety instructions for line reactors............................................................................................. 86
3.8.2 Overview of the line reactors....................................................................................................... 88
3.8.3 Line reactors for Active Line Modules......................................................................................... 89
3.8.3.1 Interface description.................................................................................................................... 89
3.8.3.2 Dimension drawings.................................................................................................................... 92
3.8.3.3 Technical data............................................................................................................................. 97
3.8.4 Damping resistor for HFD line reactors....................................................................................... 98
3.8.4.1 Description .................................................................................................................................. 98
3.8.4.2 Safety instructions for damping resistors for HFD reactors ........................................................ 98
3.8.4.3 Dimension drawings.................................................................................................................... 99
3.8.4.4 Technical data........................................................................................................................... 102
3.8.4.5 Wiring with the HFD line reactor ............................................................................................... 103
3.8.5 Line reactors for Basic Line Modules........................................................................................ 104
3.8.5.1 Interface description.................................................................................................................. 104
3.8.5.2 Dimension drawings.................................................................................................................. 107
3.8.5.3 Technical data........................................................................................................................... 110
3.8.6 Line reactors for Smart Line Modules ....................................................................................... 111
3.8.6.1 Interface description.................................................................................................................. 111
3.8.6.2 Dimension drawings.................................................................................................................. 113
3.8.6.3 Technical data........................................................................................................................... 116
3.9 Active Interface Modules internal air cooling ............................................................................ 117
3.9.1 Description ................................................................................................................................ 117
3.9.2 Safety instructions for Active Interface Modules ....................................................................... 118
3.9.3Interface description.................................................................................................................. 120
3.9.3.1 Overview ................................................................................................................................... 120
3.9.3.2 Line/load connection ................................................................................................................. 123
3.9.3.3 X121 temperature sensor and fan control................................................................................. 124
3.9.3.4 X124 Electronics power supply................................................................................................. 124
3.9.4 Connection example ................................................................................................................. 125
3.9.5 Dimension drawings.................................................................................................................. 126
3.9.6 Installation ................................................................................................................................. 130
3.9.7 Operation on an isolated-neutral system (IT system) ............................................................... 133
3.9.8 Electrical tests ........................................................................................................................... 134
3.9.9 Technical data........................................................................................................................... 135
3.10 Combining line reactors and line filters ..................................................................................... 136
3.11 Line connection variants ........................................................................................................... 137
3.11.1 Ways of connecting the line supply........................................................................................... 137

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3.11.2 Operating line connection components on the line supply ........................................................139
3.11.3 Operation of the line connection components via a transformer ...............................................140
3.11.3.1 Safety instructions for line connection components...................................................................140
3.11.3.2 Line supply connection conditions for Line Modules .................................................................141
3.11.3.3 Dimensioning an isolating transformer / autotransformer for several loads ..............................142
3.11.3.4 Operating line connection components via an autotransformer ................................................147
3.11.3.5 Operating line connection components via an isolating transformer .........................................149
4 Line Modules Booksize ....................................................................................................................... 151
4.1 Safety instructions for Line Modules Booksize ..........................................................................151
4.2 Active Line Modules with internal air cooling .............................................................................156
4.2.1 Description .................................................................................................................................156
4.2.2 Interface description...................................................................................................................157
4.2.2.1 Overview ....................................................................................................................................157
4.2.2.2 X1 line connection......................................................................................................................158
4.2.2.3 X12 fan connection ....................................................................................................................159
4.2.2.4 X21 EP terminals .......................................................................................................................159
4.2.2.5 X24 24 V terminal adapter .........................................................................................................161
4.2.2.6 X200-X202 DRIVE-CLiQ interfaces...........................................................................................161
4.2.3 Connection example ..................................................................................................................162
4.2.4 Meaning of LEDs........................................................................................................................163
4.2.5 Dimension drawings...................................................................................................................164
4.2.6 Installation ..................................................................................................................................168
4.2.7 Technical data............................................................................................................................170
4.2.7.1 Characteristics ...........................................................................................................................173
4.3 Active Line Modules with external air cooling ............................................................................176
4.3.1 Description .................................................................................................................................176
4.3.2 Interface description...................................................................................................................177
4.3.2.1 Overview ....................................................................................................................................177
4.3.2.2 X1 line connection......................................................................................................................178
4.3.2.3 X12 fan connection ....................................................................................................................179
4.3.2.4 X21 EP terminals .......................................................................................................................179
4.3.2.5 X24 24 V terminal adapter .........................................................................................................181
4.3.2.6 X200-X202 DRIVE-CLiQ interfaces...........................................................................................181
4.3.3 Connection example ..................................................................................................................182
4.3.4 Meaning of LEDs........................................................................................................................183
4.3.5 Dimension drawings...................................................................................................................184
4.3.6 Mounting ....................................................................................................................................187
4.3.7 Technical data............................................................................................................................193
4.3.7.1 Characteristics ...........................................................................................................................196
4.4 Active Line Modules with cold plate...........................................................................................199
4.4.1 Description .................................................................................................................................199
4.4.2 Interface description...................................................................................................................200
4.4.2.1 Overview ....................................................................................................................................200
4.4.2.2 X1 line connection......................................................................................................................201
4.4.2.3 X21 EP terminals .......................................................................................................................202
4.4.2.4 X24 24 V terminal adapter .........................................................................................................203
4.4.2.5 X200-X202 DRIVE-CLiQ interfaces...........................................................................................204
4.4.3 Connection example ..................................................................................................................205
4.4.4 Meaning of LEDs........................................................................................................................206
4.4.5 Dimension drawings...................................................................................................................207

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4.4.6 Mounting.................................................................................................................................... 209
4.4.7 Technical data........................................................................................................................... 212
4.4.7.1 Characteristics .......................................................................................................................... 214
4.5 Active Line Modules Liquid Cooled........................................................................................... 217
4.5.1 Description ................................................................................................................................ 217
4.5.2 Interface description.................................................................................................................. 218
4.5.2.1 Overview ................................................................................................................................... 218
4.5.2.2 X1 line connection..................................................................................................................... 219
4.5.2.3 X21 EP terminals ...................................................................................................................... 219
4.5.2.4 X24 24 V terminal adapter ........................................................................................................ 221
4.5.2.5 X200-X202 DRIVE-CLiQ interfaces .......................................................................................... 221
4.5.3 Connection example ................................................................................................................. 222
4.5.4 Meaning of LEDs....................................................................................................................... 223
4.5.5 Dimension drawing.................................................................................................................... 224
4.5.6 Installation ................................................................................................................................. 225
4.5.7 Technical data........................................................................................................................... 226
4.5.7.1 Characteristics .......................................................................................................................... 228
4.6 Basic Line Modules with internal air cooling ............................................................................. 231
4.6.1 Description ................................................................................................................................ 231
4.6.2 Interface description.................................................................................................................. 232
4.6.2.1 Overview ................................................................................................................................... 232
4.6.2.2 X1 line connection..................................................................................................................... 233
4.6.2.3 X2 braking resistor connection.................................................................................................. 234
4.6.2.4 X21 EP terminals ...................................................................................................................... 235
4.6.2.5 X24 24 V terminal adapter ........................................................................................................ 237
4.6.2.6 X200-X202 DRIVE-CLiQ interfaces .......................................................................................... 237
4.6.3 Connection examples................................................................................................................ 238
4.6.4 Meaning of LEDs....................................................................................................................... 240
4.6.5 Dimension drawings.................................................................................................................. 241
4.6.6 Installation ................................................................................................................................. 244
4.6.7 Operation on an isolated-neutral system (IT system) ............................................................... 245
4.6.8 Technical data........................................................................................................................... 246
4.6.8.1 Characteristics .......................................................................................................................... 248
4.7 Basic Line Modules with cold plate ........................................................................................... 251
4.7.1 Description ................................................................................................................................ 251
4.7.2 Interface description.................................................................................................................. 252
4.7.2.1 Overview ................................................................................................................................... 252
4.7.2.2 X1 line connection..................................................................................................................... 253
4.7.2.3 X2 braking resistor connection.................................................................................................. 254
4.7.2.4 X21 EP terminals ...................................................................................................................... 255
4.7.2.5 X24 24 V terminal adapter ........................................................................................................ 257
4.7.2.6 X200-X202 DRIVE-CLiQ interfaces .......................................................................................... 257
4.7.3 Connection examples................................................................................................................ 258
4.7.4 Meaning of LEDs....................................................................................................................... 260
4.7.5 Dimension drawings.................................................................................................................. 261
4.7.6 Mounting.................................................................................................................................... 264
4.7.7 Operation on an isolated-neutral system (IT system) ............................................................... 268
4.7.8 Technical data........................................................................................................................... 269
4.7.8.1 Characteristics .......................................................................................................................... 271
4.8 Smart Line Modules with internal air cooling ............................................................................ 274

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4.8.1 Description .................................................................................................................................274
4.8.2 Safety instructions for Smart Line Modules Booksize................................................................274
4.8.3 Interface description...................................................................................................................276
4.8.3.1 Overview ....................................................................................................................................276
4.8.3.2 X1 line connection......................................................................................................................279
4.8.3.3 X21 EP terminals .......................................................................................................................281
4.8.3.4 X22 digital inputs........................................................................................................................284
4.8.3.5 X24 24 V terminal adapter .........................................................................................................285
4.8.3.6 X200-X202 DRIVE-CLiQ interfaces...........................................................................................285
4.8.4 Connection examples ................................................................................................................286
4.8.5 Meaning of LEDs........................................................................................................................288
4.8.5.1 Smart Line Modules 5 kW and 10 kW........................................................................................288
4.8.5.2 16 kW to 55 kW Smart Line Modules.........................................................................................289
4.8.6 Dimension drawings...................................................................................................................290
4.8.7 Installation ..................................................................................................................................294
4.8.8 Technical data............................................................................................................................295
4.8.8.1 Characteristics ...........................................................................................................................297
4.9 Smart Line Modules with external air cooling ............................................................................299
4.9.1 Description .................................................................................................................................299
4.9.2 Safety instructions for Smart Line Modules Booksize................................................................299
4.9.3 Interface description...................................................................................................................301
4.9.3.1 Overview ....................................................................................................................................301
4.9.3.2 X1 line connection......................................................................................................................304
4.9.3.3 X21 EP terminals .......................................................................................................................306
4.9.3.4 X22 digital inputs........................................................................................................................309
4.9.3.5 X24 24 V terminal adapter .........................................................................................................310
4.9.3.6 X200-X202 DRIVE-CLiQ interfaces...........................................................................................310
4.9.4 Connection examples ................................................................................................................311
4.9.5 Meaning of LEDs........................................................................................................................313
4.9.5.1 Smart Line Modules 5 kW and 10 kW........................................................................................313
4.9.5.2 16 kW to 55 kW Smart Line Modules.........................................................................................314
4.9.6 Dimension drawings...................................................................................................................315
4.9.7 Mounting ....................................................................................................................................319
4.9.8 Technical data............................................................................................................................324
4.9.8.1 Characteristics ...........................................................................................................................326
4.10 Smart Line Modules with cold plate ...........................................................................................328
4.10.1Description .................................................................................................................................328
4.10.2 Safety instructions for Smart Line Modules Booksize................................................................328
4.10.3 Interface description...................................................................................................................330
4.10.3.1 Overview ....................................................................................................................................330
4.10.3.2 X1 line connection......................................................................................................................331
4.10.3.3 X21 EP terminals .......................................................................................................................332
4.10.3.4 X22 digital inputs........................................................................................................................334
4.10.3.5 X24 24 V terminal adapter .........................................................................................................334
4.10.4 Connection example ..................................................................................................................335
4.10.5 Meaning of LEDs........................................................................................................................336
4.10.6 Dimension drawings...................................................................................................................337
4.10.7 Mounting ....................................................................................................................................338
4.10.8 Technical data............................................................................................................................340
4.10.8.1 Characteristics ...........................................................................................................................342
4.10.8.2 Measuring the heat sink temperature ........................................................................................344

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5 Line Modules Booksize Compact .........................................................................................................345
5.1 Smart Line Modules Booksize Compact ................................................................................... 345
5.1.1 Description ................................................................................................................................ 345
5.1.2 Safety instructions for Smart Line Modules Booksize Compact ............................................... 345
5.1.3 Interface description.................................................................................................................. 350
5.1.3.1 Overview ................................................................................................................................... 350
5.1.3.2 X1 line connection..................................................................................................................... 351
5.1.3.3 X21 EP terminals ...................................................................................................................... 351
5.1.3.4 X24 24 V terminal adapter ........................................................................................................ 353
5.1.3.5 X200-X202 DRIVE-CLiQ interfaces .......................................................................................... 353
5.1.4 Connection example ................................................................................................................. 354
5.1.5 Meaning of the LEDs................................................................................................................. 355
5.1.6 Dimension drawing.................................................................................................................... 356
5.1.7 Mounting.................................................................................................................................... 357
5.1.8 Technical data........................................................................................................................... 359
5.1.8.1 Characteristics .......................................................................................................................... 361
6 Motor Modules Booksize......................................................................................................................363
6.1 Safety instructions for Motor Modules Booksize....................................................................... 363
6.2 Motor Modules with internal air cooling..................................................................................... 368
6.2.1 Description ................................................................................................................................ 368
6.2.2 Interface description.................................................................................................................. 369
6.2.2.1 Overview ................................................................................................................................... 369
6.2.2.2 Motor and brake connection...................................................................................................... 371
6.2.2.3 X12 fan connection ................................................................................................................... 373
6.2.2.4 X21/X22 EP terminals/temperature sensor............................................................................... 374
6.2.2.5 X200-X203 DRIVE-CLiQ interface............................................................................................ 375
6.2.3 Connection examples................................................................................................................ 376
6.2.4 Meaning of LEDs....................................................................................................................... 378
6.2.5 Dimension drawings.................................................................................................................. 379
6.2.6 Installation ................................................................................................................................. 384
6.2.7 Technical data........................................................................................................................... 386
6.2.7.1 Single Motor Modules ............................................................................................................... 386
6.2.7.2 Double Motor Modules .............................................................................................................. 388
6.2.7.3 Characteristics .......................................................................................................................... 389
6.2.8 Technical data for Motor Modules Booksize with 300% overload ............................................ 393
6.2.8.1 Single Motor Modules (300% overload).................................................................................... 393
6.2.8.2 Double Motor Modules (300% overload) .................................................................................. 395
6.2.8.3 Characteristics for Motor Modules Booksize with 300% overload............................................ 397
6.3 Motor Module with external air cooling ..................................................................................... 401
6.3.1 Description ................................................................................................................................ 401
6.3.2 Interface description.................................................................................................................. 402
6.3.2.1 Overview ................................................................................................................................... 402
6.3.2.2 Motor and brake connection...................................................................................................... 404
6.3.2.3 X12 fan connection ................................................................................................................... 406
6.3.2.4 X21/X22 EP terminals/temperature sensor............................................................................... 407
6.3.2.5 X200-X203 DRIVE-CLiQ interface............................................................................................ 408
6.3.3 Connection examples................................................................................................................ 409
6.3.4 Meaning of LEDs....................................................................................................................... 411
6.3.5 Dimension drawings.................................................................................................................. 412
6.3.6 Mounting.................................................................................................................................... 417

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6.3.7 Technical data............................................................................................................................423
6.3.7.1 Single Motor Modules ................................................................................................................423
6.3.7.2 Double Motor Modules...............................................................................................................426
6.3.7.3 Characteristics ...........................................................................................................................427
6.3.8 Technical data for Motor Modules Booksize with 300% overload .............................................431
6.3.8.1 Single Motor Modules (300% overload).....................................................................................431
6.3.8.2 Characteristics for Motor Modules Booksize with 300% overload.............................................435
6.4 Motor Modules with cold plate ...................................................................................................439
6.4.1 Description .................................................................................................................................439
6.4.2 Interface description...................................................................................................................440
6.4.2.1 Overview ....................................................................................................................................440
6.4.2.2 Motor and brake connection ......................................................................................................442
6.4.2.3 X21/X22 EP terminals/temperature sensor ...............................................................................444
6.4.2.4 X200-X203 DRIVE-CLiQ interface.............................................................................................446
6.4.3 Connection examples ................................................................................................................447
6.4.4 Meaning of LEDs........................................................................................................................449
6.4.5 Dimension drawings...................................................................................................................450
6.4.6 Mounting ....................................................................................................................................454
6.4.7 Technical data............................................................................................................................457
6.4.7.1 Single Motor Modules ................................................................................................................457
6.4.7.2 Double Motor Modules...............................................................................................................459
6.4.7.3 Characteristics ...........................................................................................................................460
6.4.8 Technical data for Motor Modules Booksize with 300% overload .............................................464
6.4.8.1 Single Motor Modules (300% overload).....................................................................................464
6.4.8.2 Double Motor Modules (300% overload) ...................................................................................466
6.4.8.3 Characteristics for Motor Modules Booksize with 300% overload.............................................468
6.5 Motor Modules Liquid Cooled ....................................................................................................472
6.5.1 Description .................................................................................................................................472
6.5.2 Interface description...................................................................................................................473
6.5.2.1 Overview ....................................................................................................................................473
6.5.2.2 Motor and brake connection ......................................................................................................474
6.5.2.3 X21 EP terminal/temperature sensor.........................................................................................475
6.5.2.4 X200-X202 DRIVE-CLiQ interface.............................................................................................477
6.5.3 Connection example ..................................................................................................................477
6.5.4 Meaning of LEDs........................................................................................................................478
6.5.5 Dimension drawing ....................................................................................................................479
6.5.6 Installation ..................................................................................................................................480
6.5.7 Technical data............................................................................................................................482
6.5.7.1 Characteristics ...........................................................................................................................483
7 Motor Modules Booksize Compact ...................................................................................................... 487
7.1 Safety instructions for Motor Modules Booksize Compact ........................................................487
7.2 Description .................................................................................................................................491
7.3 Interface description...................................................................................................................492
7.3.1 Overview ....................................................................................................................................492
7.3.2 X1/X2 motor connection.............................................................................................................494
7.3.3 X11/X12 motor brake connection...............................................................................................494
7.3.4 X21/X22 EP terminals/temperature sensor ...............................................................................495
7.3.5 X200-X203 DRIVE-CLiQ interface.............................................................................................497
7.4 Connection example ..................................................................................................................498

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7.5 Meaning of LEDs....................................................................................................................... 499
7.6 Dimension drawings.................................................................................................................. 500
7.7 Mounting.................................................................................................................................... 503
7.8 Technical data........................................................................................................................... 505
7.8.1 Single Motor Modules ............................................................................................................... 505
7.8.2 Double Motor Modules .............................................................................................................. 506
7.8.3 Characteristics .......................................................................................................................... 508
8 DC link components.............................................................................................................................513
8.1 Safety instructions for DC link components .............................................................................. 513
8.2 Braking Module Booksize.......................................................................................................... 516
8.2.1 Description ................................................................................................................................ 516
8.2.2 Safety instructions for Braking Modules Booksize.................................................................... 517
8.2.3 Interface description.................................................................................................................. 518
8.2.3.1 Overview ................................................................................................................................... 518
8.2.3.2 X1 braking resistor connection.................................................................................................. 519
8.2.3.3 X21 digital inputs/outputs.......................................................................................................... 520
8.2.4 Connection example ................................................................................................................. 522
8.2.5 Meaning of LEDs....................................................................................................................... 523
8.2.6 Dimension drawing.................................................................................................................... 524
8.2.7 Installation ................................................................................................................................. 525
8.2.8 Technical data........................................................................................................................... 526
8.2.8.1 Characteristic curves................................................................................................................. 526
8.2.9 Configuration instructions.......................................................................................................... 527
8.3 Braking Module Booksize Compact .......................................................................................... 528
8.3.1 Description ................................................................................................................................ 528
8.3.2 Safety instructions for Braking Modules Booksize Compact .................................................... 530
8.3.3 Interface description.................................................................................................................. 531
8.3.3.1 Overview ................................................................................................................................... 531
8.3.3.2 X1 braking resistor connection.................................................................................................. 532
8.3.3.3 X21 digital inputs/outputs.......................................................................................................... 533
8.3.3.4 X22 digital output/temperature switch....................................................................................... 534
8.3.3.5 DIP switch ................................................................................................................................. 534
8.3.4 Connection examples................................................................................................................ 535
8.3.5 Meaning of LEDs....................................................................................................................... 537
8.3.6 Dimension drawing.................................................................................................................... 538
8.3.7 Mounting.................................................................................................................................... 539
8.3.8 Technical specifications ............................................................................................................ 541
8.3.8.1 Characteristic curves................................................................................................................. 542
8.3.9 Configuration instructions.......................................................................................................... 543
8.4 Braking units for 100 kW Basic Line Modules........................................................................... 544
8.4.1 Description ................................................................................................................................ 544
8.4.2 Safety instructions for Braking Modules for the 100 kW Basic Line Module ............................ 544
8.4.3 Interface description.................................................................................................................. 546
8.4.3.1 X3 DC link connection............................................................................................................... 546
8.4.3.2 X6 braking resistor connection.................................................................................................. 546
8.4.3.3 Switch S1 .................................................................................................................................. 547
8.4.4 Connection example ................................................................................................................. 548
8.4.5 Dimension drawing.................................................................................................................... 549

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8.4.6 Connection to the Basic Line Module 100 kW...........................................................................550
8.5 Capacitor Module.......................................................................................................................552
8.5.1 Description .................................................................................................................................552
8.5.2 Safety instructions for Capacitor Modules .................................................................................552
8.5.3 Interface description...................................................................................................................553
8.5.3.1 Overview ....................................................................................................................................553
8.5.4 Dimension drawing ....................................................................................................................554
8.5.5 Mounting ....................................................................................................................................555
8.5.6 Technical Specifications ............................................................................................................556
8.6 Control Supply Module CSM......................................................................................................557
8.6.1 Description .................................................................................................................................557
8.6.2 Safety instructions for Control Supply Modules .........................................................................558
8.6.3 Interface description...................................................................................................................560
8.6.3.1 Overview ....................................................................................................................................560
8.6.3.2 X1 line connection......................................................................................................................561
8.6.3.3 X21 signaling contact.................................................................................................................561
8.6.3.4 X24 24 V terminal adapter .........................................................................................................562
8.6.3.5 S1 DIP switch.............................................................................................................................562
8.6.4 Connection examples ................................................................................................................563
8.6.4.1 Single operation .........................................................................................................................564
8.6.4.2 Parallel operation .......................................................................................................................566
8.6.5 Meaning of LEDs........................................................................................................................571
8.6.6 Dimension drawing ....................................................................................................................572
8.6.7 Installation ..................................................................................................................................573
8.6.8 Technical data............................................................................................................................574
8.6.8.1 Characteristics ...........................................................................................................................575
9 Braking resistors ................................................................................................................................. 577
9.1 Description .................................................................................................................................577
9.2 Safety instructions for braking resistors .....................................................................................578
9.3 Dimension drawings...................................................................................................................579
9.4 Technical data............................................................................................................................586
9.4.1 Characteristic curves .................................................................................................................587
10 Motor-side power components ............................................................................................................ 589
10.1 Motor reactors............................................................................................................................589
10.1.1 Description .................................................................................................................................589
10.1.2 Safety instructions for motor reactors ........................................................................................589
10.1.3 Dimension drawings...................................................................................................................591
10.1.4 Technical data............................................................................................................................596
10.2 Voltage Protection Module VPM................................................................................................598
10.2.1 Description .................................................................................................................................598
10.2.2 Safety instructions for Voltage Protection Modules ...................................................................599
10.2.3 Interface description...................................................................................................................601
10.2.3.1 Overview ....................................................................................................................................601
10.2.3.2 Signaling interface X3 ................................................................................................................603
10.2.3.3 Connection bars U, V, W, PE.....................................................................................................604
10.2.4 Connection examples ................................................................................................................605
10.2.5 Dimension drawings...................................................................................................................607

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10.2.6 Installation ................................................................................................................................. 609
10.2.7 Electrical connection ................................................................................................................. 611
10.2.7.1 Connecting signaling contact X3............................................................................................... 612
10.2.7.2 Connecting power cables (using the VPM 200 Dynamik as an example) ................................ 613
10.2.8 Technical data........................................................................................................................... 616
11 Accessories .........................................................................................................................................617
11.1 Shield connecting plates for power supply and motor cables................................................... 617
11.1.1 Description ................................................................................................................................ 617
11.1.2 Shield connecting plates ........................................................................................................... 617
11.1.3 Overview examples................................................................................................................... 620
11.1.4 Dimension drawings.................................................................................................................. 624
11.1.4.1 Line Modules and Motor Modules with internal air cooling ....................................................... 624
11.1.4.2 Line Modules and Motor Modules with external air cooling ...................................................... 628
11.1.4.3 Line Modules and Motor Modules with cold plate..................................................................... 632
11.1.4.4 Line Modules and Motor Modules, Liquid Cooled..................................................................... 636
11.1.4.5 Active Interface Modules........................................................................................................... 637
11.1.5 Installation ................................................................................................................................. 640
11.1.6 Connecting the power cables.................................................................................................... 643
11.2 Releasing the DC link protective cover ..................................................................................... 645
11.3 Reinforced DC link busbars ...................................................................................................... 646
11.3.1 Description ................................................................................................................................ 646
11.3.2 Safety instructions for reinforced DC link busbars.................................................................... 647
11.3.3 Dimension drawings.................................................................................................................. 648
11.3.4 Removing the DC link busbars ................................................................................................. 649
11.3.5 Installing the reinforced DC link busbars .................................................................................. 650
11.4 DC link rectifier adapter for Booksize format ............................................................................ 651
11.4.1 Description ................................................................................................................................ 651
11.4.2 Safety instructions for DC link rectifier adapters ....................................................................... 653
11.4.3 Interface description.................................................................................................................. 655
11.4.3.1 Overview ................................................................................................................................... 655
11.4.3.2 DC link connection .................................................................................................................... 655
11.4.4 Dimension drawings.................................................................................................................. 656
11.4.5 Mounting.................................................................................................................................... 658
11.4.5.1 Installation on components that are 50 mm and 100 mm wide ................................................ 658
11.4.5.2 Installation on components that are 150 mm, 200 mm and 300 mm wide ............................... 660
11.4.6 Electrical connection ................................................................................................................. 662
11.4.7 Technical specifications ............................................................................................................ 663
11.5 DC link adapter ......................................................................................................................... 664
11.5.1 Description ................................................................................................................................ 664
11.5.2 Safety instructions for DC link adapters.................................................................................... 664
11.5.3 Interface description.................................................................................................................. 667
11.5.3.1 Overview ................................................................................................................................... 667
11.5.3.2 DC link connection .................................................................................................................... 667
11.5.4 Dimension drawing.................................................................................................................... 669
11.5.5Installation ................................................................................................................................. 670
11.5.6 Electrical connection ................................................................................................................. 674
11.5.6.1 Preparing the cables ................................................................................................................. 674
11.5.6.2 Fixing the cables to the rear cabinet panel ............................................................................... 675
11.5.6.3 Cable connection and shield support........................................................................................ 676