Siemens SINAMICS S120 User manual

Manual 01/2013
Chassis Power Units
SINAMICS S120
SINAMICS
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SINAMICS
S120
Chassis power units
Manual
(GH3), 01/2013
6SL3097-4AE00-0BP3
Preface
System overview
1
Line-side power components
2
Line Modules
3
Motor Modules
4
DC link components
5
Motor-side power
components
6
Cabinet design and EMC
7
Maintenance and Servicing
8
Appendix
A

Siemens AG
Industry Sector
Postfach 48 48
90026 NÜRNBERG
GERMANY
Order number: 6SL3097-4AE00-0BP3
Ⓟ 07/2013 Technical data subject to change
Copyright © Siemens AG 2004 - 2013.
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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Preface
SINAMICS documentation
The SINAMICS documentation is organized in the following categories:
● General documentation/catalogs
● User documentation
● Manufacturer/service documentation
Additional information
Using the following link, you can find 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
Using the following link, you can find 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
Using the following link, you can find information on SITRAIN - training from Siemens for
products, systems and drive technology solutions:
http://www.siemens.com/sitrain
FAQs
You can find Frequently Asked Questions in the Service&Support pages under Product
Support:
http://support.automation.siemens.com

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SINAMICS
You can find information on SINAMICS under:
http://www.siemens.com/sinamics
Usage phases and the available tools/documents
Table 1 Usage phases and the available tools/documents
Usage phase Tools
Orientation SINAMICS S sales documentation
Planning/engineering •SIZER engineering tool
•Configuration manuals, motors
Decision making/ordering SINAMICS S Catalogs
Configuring/installation •SINAMICS S120 Manual for Control Units and Additional System
Components
•SINAMICS S120 Manual for Booksize Power Units
•SINAMICS S120 Manual for Chassis Power Units
•SINAMICS S120 Manual for Liquid Cooled Chassis Power Units
•SINAMICS S120 Manual for AC Drives
•SINAMICS S120M Manual for Distributed Drive Technology
Commissioning •STARTER Commissioning Tool
•SINAMICS S120 Getting Started
•SINAMICS S120 Commissioning Manual
•SINAMICS S120 CANopen Commissioning Manual
•SINAMICS S120 Function Manual
•SINAMICS S120/S150 List Manual
Using/operating •SINAMICS S120 Commissioning Manual
•SINAMICS S120/S150 List Manual
Maintenance/Service •SINAMICS S120 Commissioning Manual
•SINAMICS S120/S150 List Manual
List of 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 provides all the information, procedures and operational instructions required
for commissioning and servicing SINAMICS S120.

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Standard scope
The scope of the functionality described in this document can differ from the scope of the
functionality of the drive system that is actually supplied.
● 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 controller or when servicing.
● The documentation can also contain descriptions of functions that are not available in a
particular product version of the drive system. The functionalities 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. This documentation cannot take into consideration every
conceivable type of installation, operation and service/maintenance.
Technical support
Country-specific telephone numbers for technical support are provided in the Internet under
Contact:
http://www.siemens.com/automation/service&support
EC declarations of conformity
The EC Declaration of Conformity for the EMC Directive and for the Low-Voltage Directive
can be found/obtained from the relevant regional office of the I DT MC and I DT LD Business
Units of Siemens AG.
Note
Low-voltage directive
When operated in dry operating areas, SINAMICS equipment with AC motors conforms to
Low-Voltage Directive 2006/95/EC.
Note
EC declaration of conformity
In the configuration specified in the corresponding EC Declaration of Conformity regarding
EMC requirements and when the EMC installation guideline, order no. 6FC5297-0AD30-0*P*
is observed, SINAMICS devices conform to EMC Directive 89/336/EEC and 2004/108/EC.
(*A: German; *B: English)
Note
Machinery directive
The devices satisfy the requirements according to Machinery Directive 2006/42/EC for the
Safety Integrated safety functions.

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Note
Compliance with EMC limit values
The manual describes a target state which, if maintained, ensures the required level of
operational reliability and compliance with EMC limit values.
Should there be any deviation from the requirements in the manual, appropriate actions (e.g.
measurements) must be taken to check/prove that the required level of operational reliability
and compliance with EMC limit values are ensured.
EMC limit values for South Korea
The EMC limit values that have to be observed for South Korea correspond to the limit
values of the EMC product standard for variable-speed electric drives EN 61800-3 of
category C2 or of limit value class A, Group 1 according to EN 55011.
With suitable additional measures, the limit values of category C2 or of limit class A, Group
1, are maintained. Additional measures, such as the use of an additional RFI suppression
filter (EMC filter), may be necessary.
In addition, measures for a correct EMC-compliant configuration of the plant are described in
detail in this manual and the "SINAMICS Low-Voltage Configuration Manual".
Spare parts
You will find spare parts on the Internet at:
http://support.automation.siemens.com/WW/view/en/16612315
Test certificates
The Safety Integrated functions of SINAMICS components are generally certified by
independent institutes. An up-to-date list of certified components is available on request from
your local Siemens office. If you have any questions relating to certifications that have not
been completed, please ask your Siemens contact.

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ESD information
CAUTION
Electrostatic sensitive devices
Electrostatic sensitive devices (ESD) are single components, integrated circuits or devices
that can be damaged by electrostatic fields or electrostatic discharges.
Regulations for handling ESD components:
•During the handling of electronic components, pay attention to the grounding of the
person, workplace and packaging!
•Personnel in ESD areas with conductive flooring may only handle electronic
components if:
– They are grounded with an ESD wrist band
– They are wearing ESD shoes or ESD shoe grounding straps
•Electronic components should be touched only when this is unavoidable. They must
only be handled on the front panel or, in the case of printed circuit boards, at the edge.
•Electronic components must not be brought into contact with plastics or clothing made
of artificial fibers.
•Electronic components may only be placed on conducting surfaces (table with ESD
coating, conducting ESD foamed material, ESD packing bag, ESD transport container).
•Electronic components may not be placed near display units, monitors or televisions
(minimum distance from the 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).

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Safety information
DANGER
Qualified personnel
SINAMICS S equipment must only be commissioned by suitably qualified personnel.
The personnel must take into account the information provided in the technical customer
documentation for the product, and be familiar with and follow the specified danger and
warning notices.
When electrical equipment and motors are operated, the electrical circuits automatically
conduct a dangerous voltage.
Dangerous mechanical movements of the driven machine components are possible during
system operations.
All work on the electrical system must be carried out when the system has been
disconnected from the power supply and is de-energized.
DANGER
Five safety rules
When carrying out any kind of work on electrical devices, the "five safety rules" according to
EN 50110 must always be observed:
1. Disconnect the system.
2. Protect against reconnection.
3. Make sure that the equipment is de-energized.
4. Ground and short-circuit.
5. Cover or enclose adjacent components that are still live.
WARNING
Correct and safe operation
Correct and safe operation of SINAMICS S units assumes correct transportation in the
transport 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 plant-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
may be connected to any of the connections or terminals on the electronics modules.

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Note
Installation of a UL-approved system
For a UL-approved system use 60/75° C copper conductors only.
NOTICE
Malfunctions caused by mobile telephones
Operating the equipment in the immediate vicinity (< 1.8 m) of mobile telephones with a
transmitting power of > 1 W may cause the devices to malfunction.

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Residual risks of power drive systems
The control and drive components of a power drive system (PDS) are approved for industrial
and commercial use in industrial line supplies. Their use in public electrical networks
requires a different configuration and/or additional measures.
These components may only be operated in closed housings or in higher-level control
cabinets with protective covers that are closed, and when all of the protective devices are
used.
These components may only be handled by qualified and trained technical personnel who
are knowledgeable and observe all of the safety information and instructions on the
components and in the associated technical user documentation.
When carrying out a risk assessment of the machine/plant according to the EU Machinery
Directive, the machine manufacturer / plant operator 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 outside specification
– Condensation / conductive contamination
– Parameterization, programming, cabling, and installation errors
– Use of radio devices / cellular phones in the immediate vicinity of the controller
– External influences / damage
2. In the event of a fault, exceptionally high temperatures, including open fire, as well as
emissions of light, noise, particles, gases, etc. can occur inside and outside the converter,
for example:
– Component malfunctions
– Software errors
– Operating and/or ambient conditions outside specification
– External influences / damage
Converters of the Open Type/IP20 degree of protection must be installed in a control
cabinet (or protected by another equivalent measure) in such a way that contact with
fire inside and outside the converter is prevented.
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 outside specification
– Condensation / conductive contamination
– External influences / damage

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4. Electrical, magnetic and electromagnetic fields generated in operation that can pose a
risk to people with a pacemaker, implants or metal replacement joints, etc. if they are too
close.
5. Release of environmental pollutants or emissions as a result of improper operation of the
system and/or failure to dispose of components safely and correctly.
Note
The components must be protected against conductive pollution (e.g. by installing them in a
cabinet with degree of protection IP54B according to EN 60529).
Provided conductive pollution can be prevented at the installation site, the degree of
protection for the cabinet can be decreased accordingly.
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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Electromagnetic fields
WARNING
Electromagnetic fields "electro smog"
Electromagnetic fields are generated by the operation of electrical power engineering
installations such as transformers, converters or motors.
Electromagnetic fields can interfere with electronic devices, which could cause them to
malfunction. For example, the operation of heart pacemakers can be impaired, potentially
leading to damage to a person's health or even death. It is therefore forbidden for persons
with heart pacemakers to enter these areas.
The plant operator is responsible for taking appropriate measures (labels and hazard
warnings) to adequately protect operating personnel and others against any possible risk.
•Observe the relevant nationally applicable health and safety regulations. In Germany,
"electromagnetic fields" are subject to regulations BGV B11 and BGR B11 stipulated by
the German statutory industrial accident insurance institution.
•Display adequate hazard warning notices.
•Place barriers around hazardous areas.
•Take measures, e.g. using shields, to reduce electromagnetic fields at their source.
•Make sure that personnel are wearing the appropriate protective gear.

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Table of contents
Preface ...................................................................................................................................................... 3
1 System overview...................................................................................................................................... 19
1.1 The SINAMICS range of drives....................................................................................................19
1.2 SINAMICS S120 drive system.....................................................................................................22
1.3 Technical specifications ...............................................................................................................26
1.4 Derating factors as a function of installation altitude and ambient temperature..........................29
1.5 Standards.....................................................................................................................................30
1.6 Basic structure of a drive system with SINAMICS S120 .............................................................33
1.6.1 Structure of a drive system with SINAMICS S120 and regulated infeed.....................................33
1.6.2 Structure of a drive system with SINAMICS S120 and unregulated infeed / regenerative
feedback.......................................................................................................................................34
1.6.3 Structure of a drive system with SINAMICS S120 and unregulated infeed.................................35
2 Line-side power components................................................................................................................... 37
2.1 General ........................................................................................................................................37
2.2 Line filters for Basic Line Modules ...............................................................................................37
2.2.1 Description ...................................................................................................................................37
2.2.2 Safety information ........................................................................................................................37
2.2.3 Dimension drawing ......................................................................................................................39
2.2.4 Technical data..............................................................................................................................41
2.3 Line filters for Smart Line Modules and Active Line Modules......................................................43
2.3.1 Description ...................................................................................................................................43
2.3.2 Safety information ........................................................................................................................43
2.3.3 Dimension drawing ......................................................................................................................45
2.3.4 Technical data..............................................................................................................................48
2.4 Line reactors for Basic Line Modules...........................................................................................49
2.4.1 Description ...................................................................................................................................49
2.4.2 Safety information ........................................................................................................................49
2.4.3 Dimension drawing ......................................................................................................................50
2.4.4 Technical data..............................................................................................................................52
2.5 Line reactors for Smart Line Modules..........................................................................................54
2.5.1 Description ...................................................................................................................................54
2.5.2 Safety information ........................................................................................................................54
2.5.3 Dimension drawing ......................................................................................................................55
2.5.4 Technical data..............................................................................................................................61
2.6 Active Interface Modules..............................................................................................................62
2.6.1 Description ...................................................................................................................................62
2.6.2 Safety information ........................................................................................................................63
2.6.3 Interface description.....................................................................................................................64
2.6.3.1 Overview ......................................................................................................................................64
2.6.3.2 Connection example ....................................................................................................................68

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2.6.3.3 Line/load connection ................................................................................................................... 70
2.6.3.4 DRIVE-CLiQ interface X500........................................................................................................ 70
2.6.3.5 X530 neutral point grounding...................................................................................................... 71
2.6.3.6 X609 terminal strip ...................................................................................................................... 72
2.6.3.7 Meaning of the LED on the Voltage Sensing Module (VSM) in the Active Interface Module ..... 73
2.6.4 Dimension drawing...................................................................................................................... 74
2.6.5 Electrical connection ................................................................................................................... 78
2.6.6 Technical data............................................................................................................................. 84
3 Line Modules ........................................................................................................................................... 87
3.1 Introduction ................................................................................................................................. 87
3.2 Basic Line Modules..................................................................................................................... 88
3.2.1 Description .................................................................................................................................. 88
3.2.2 Safety information ....................................................................................................................... 90
3.2.3 Interface description.................................................................................................................... 91
3.2.3.1 Overview ..................................................................................................................................... 91
3.2.3.2 Connection example ................................................................................................................... 93
3.2.3.3 Line/load connection ................................................................................................................... 95
3.2.3.4 X9 terminal strip .......................................................................................................................... 95
3.2.3.5 X41 EP terminal / temperature sensor connection ..................................................................... 96
3.2.3.6 X42 terminal strip ........................................................................................................................ 97
3.2.3.7 DRIVE-CLiQ interfaces X400, X401, X402.................................................................................98
3.2.3.8 Meaning of the LEDs on the Control Interface Module in the Basic Line Module ...................... 99
3.2.4 Dimension drawing.................................................................................................................... 100
3.2.5 Electrical connection ................................................................................................................. 102
3.2.6 Precharging circuit for the Basic Line Modules, frame size GD................................................ 106
3.2.7 Technical data........................................................................................................................... 109
3.3 Smart Line Modules .................................................................................................................. 118
3.3.1 Description ................................................................................................................................ 118
3.3.2 Safety information ..................................................................................................................... 121
3.3.3 Interface description.................................................................................................................. 123
3.3.3.1 Overview ................................................................................................................................... 123
3.3.3.2 Connection example ................................................................................................................. 126
3.3.3.3 Line/load connection ................................................................................................................. 127
3.3.3.4 X9 terminal strip ........................................................................................................................ 128
3.3.3.5 X41 EP terminal / temperature sensor connection ................................................................... 128
3.3.3.6 X42 terminal strip ...................................................................................................................... 129
3.3.3.7 DRIVE-CLiQ interfaces X400, X401, X402............................................................................... 130
3.3.3.8 Meaning of the LEDs on the Control Interface Module in the Smart Line Module.................... 131
3.3.4 Dimension drawing.................................................................................................................... 132
3.3.5 Electrical connection ................................................................................................................. 135
3.3.6 Technical data........................................................................................................................... 141
3.4 Active Line Modules .................................................................................................................. 148
3.4.1 Description ................................................................................................................................ 148
3.4.2 Safety information ..................................................................................................................... 151
3.4.3 Interface description.................................................................................................................. 152
3.4.3.1 Overview ................................................................................................................................... 152
3.4.3.2 Connection example ................................................................................................................. 156
3.4.3.3 Line/load connection ................................................................................................................. 157
3.4.3.4 X9 terminal strip ........................................................................................................................ 158
3.4.3.5 X41 EP terminal / temperature sensor connection ................................................................... 158

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3.4.3.6 X42 terminal strip .......................................................................................................................159
3.4.3.7 DRIVE-CLiQ interfaces X400, X401, X402................................................................................160
3.4.3.8 Meaning of the LEDs on the Control Interface Module in the Active Line Module ....................161
3.4.4 Dimension drawing ....................................................................................................................162
3.4.5 Electrical connection ..................................................................................................................166
3.4.6 Technical specifications .............................................................................................................168
4 Motor Modules....................................................................................................................................... 177
4.1 Description .................................................................................................................................177
4.2 Safety information ......................................................................................................................179
4.3 Interface description...................................................................................................................180
4.3.1 Overview ....................................................................................................................................180
4.3.2 Connection example ..................................................................................................................184
4.3.3 DC link/motor connection...........................................................................................................185
4.3.4 X9 terminal strip .........................................................................................................................186
4.3.5 DCPS, DCNS connection for a dv/dt filter .................................................................................186
4.3.6 X41 EP terminal / temperature sensor connection ....................................................................187
4.3.7 X42 terminal strip .......................................................................................................................188
4.3.8 X46 Brake control and monitoring .............................................................................................188
4.3.9 DRIVE-CLiQ interfaces X400, X401, X402................................................................................189
4.3.10 Meaning of the LEDs on the Control Interface Module in the Motor Module.............................190
4.4 Dimension drawing ....................................................................................................................191
4.5 Electrical connection ..................................................................................................................195
4.6 Technical specifications .............................................................................................................197
4.6.1 510 V DC – 750 V DC Motor Modules .......................................................................................197
4.6.2 675 V DC – 1080 V DC Motor Modules .....................................................................................203
4.6.3 Overload capability ....................................................................................................................210
4.6.4 Current de-rating depending on the pulse frequency ................................................................212
4.6.5 Parallel connection of Motor Modules........................................................................................214
5 DC link components............................................................................................................................... 217
5.1 Braking Module ..........................................................................................................................217
5.1.1 Description .................................................................................................................................217
5.1.2 Safety information ......................................................................................................................219
5.1.3 Interface description...................................................................................................................220
5.1.3.1 Braking Module for frame sizes FX, FB .....................................................................................220
5.1.3.2 Braking Module for frame sizes GX, GB, GD ............................................................................221
5.1.3.3 Braking Module for frame sizes HX, JX .....................................................................................222
5.1.3.4 Connection example ..................................................................................................................223
5.1.3.5 Braking resistor connection........................................................................................................223
5.1.3.6 X21 digital inputs/outputs...........................................................................................................224
5.1.3.7 S1 Threshold switch...................................................................................................................225
5.1.4 Installation..................................................................................................................................227
5.1.4.1 Installing the Braking Module in an Active Line Module / Motor Module, frame size FX...........227
5.1.4.2 Installing the Braking Module in a Smart Line Module / Active Line Module / Motor
Module, frame size GX ..............................................................................................................230
5.1.4.3 Installing the Braking Module in a Smart Line Module / Active Line Module / Motor
Module, frame size HX...............................................................................................................233

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5.1.4.4 Installing the Braking Module in a Smart Line Module / Active Line Module / Motor
Module, frame size JX............................................................................................................... 234
5.1.4.5 Installing the Braking Module in a Basic Line Module, frame size FB ...................................... 235
5.1.4.6 Installing the Braking Module in a Basic Line Module, frame size GB, GD .............................. 237
5.1.5 Technical specifications ............................................................................................................ 239
5.2 Braking resistors ....................................................................................................................... 242
5.2.1 Description ................................................................................................................................ 242
5.2.2 Safety information ..................................................................................................................... 243
5.2.3 Dimension drawing.................................................................................................................... 244
5.2.4 Electrical connection ................................................................................................................. 245
5.2.5 Technical data........................................................................................................................... 246
6 Motor-side power components............................................................................................................... 249
6.1 Sine-wave filter.......................................................................................................................... 249
6.1.1 Description ................................................................................................................................ 249
6.1.2 Safety information ..................................................................................................................... 250
6.1.3 Dimension drawing.................................................................................................................... 251
6.1.4 Technical data........................................................................................................................... 252
6.2 Motor reactors ........................................................................................................................... 253
6.2.1 Description ................................................................................................................................ 253
6.2.2 Safety information ..................................................................................................................... 253
6.2.3 Dimension drawing.................................................................................................................... 255
6.2.4 Technical data........................................................................................................................... 259
6.3 dv/dt filter plus Voltage Peak Limiter......................................................................................... 263
6.3.1 Description ................................................................................................................................ 263
6.3.2 Safety information ..................................................................................................................... 265
6.3.3 Interface description.................................................................................................................. 266
6.3.4 Connecting the dv/dt filter plus Voltage Peak Limiter ............................................................... 268
6.3.5 Dimension drawing, dv/dt reactor ............................................................................................. 270
6.3.6 Dimension drawing of the Voltage Peak Limiter ....................................................................... 273
6.3.7 Technical data........................................................................................................................... 276
6.4 dv/dt filter compact plus Voltage Peak Limiter.......................................................................... 283
6.4.1 Description ................................................................................................................................ 283
6.4.2 Safety information ..................................................................................................................... 286
6.4.3 Interface description.................................................................................................................. 287
6.4.4 Connecting the dv/dt filter compact plus Voltage Peak Limiter................................................. 290
6.4.5 Dimension drawing for dv/dt filter compact plus Voltage Peak Limiter..................................... 293
6.4.6 Technical data........................................................................................................................... 298
7 Cabinet design and EMC....................................................................................................................... 303
7.1 Information ................................................................................................................................ 303
7.1.1 General...................................................................................................................................... 303
7.1.2 Safety information ..................................................................................................................... 303
7.1.3 Insulation test ............................................................................................................................ 306
7.1.4 Directives................................................................................................................................... 307
7.2 EMC-compliant design and control cabinet configuration......................................................... 307
7.3 Cabinet air conditioning............................................................................................................. 308
7.3.1 General...................................................................................................................................... 308
7.3.2 Ventilation.................................................................................................................................. 309

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8 Maintenance and Servicing.................................................................................................................... 319
8.1 Chapter content .........................................................................................................................319
8.2 Maintenance...............................................................................................................................319
8.3 Maintenance...............................................................................................................................320
8.3.1 Installation device ......................................................................................................................322
8.3.2 Using crane lifting lugs to transport power blocks .....................................................................323
8.4 Replacing components ..............................................................................................................326
8.4.1 Safety information ......................................................................................................................326
8.4.2 Replacing the power block, Active Line Module, and Motor Module, frame size FX.................327
8.4.3 Replacing the power block, Smart Line Module, Active Line Module, and Motor Module,
frame size GX ............................................................................................................................330
8.4.4 Replacing the power block, Smart Line Module, Active Line Module, and Motor Module,
frame size HX.............................................................................................................................333
8.4.5 Replacing the power block, Smart Line Module, Active Line Module, and Motor Module,
frame size JX .............................................................................................................................338
8.4.6 Replacing the power block, Basic Line Module, frame size FB.................................................340
8.4.7 Replacing the power block, Basic Line Module GB, GD ...........................................................343
8.4.8 Replacing the Control Interface Module, Active Line Module and Motor Module, frame
size FX .......................................................................................................................................346
8.4.9 Replacing the Control Interface Module, Smart Line Module, Active Line Module, and
Motor Module, frame size GX ....................................................................................................348
8.4.10 Replacing the Control Interface Module, Smart Line Module, Active Line Module, and
Motor Module, frame size HX ....................................................................................................350
8.4.11 Replacing the Control Interface Module, Smart Line Module, Active Line Module, and
Motor Module, frame size JX .....................................................................................................352
8.4.12 Replacing the Control Interface Module, Basic Line Module, frame size FB ............................354
8.4.13 Replacing the Control Interface Module, Basic Line Module, frame size GB, GD ....................356
8.4.14 Replacing the fan, Smart Line Module, Active Line Module, and Motor Module, frame
sizes FX, GX ..............................................................................................................................358
8.4.15 Replacing the fan, Smart Line Module, Active Line Module, and Motor Module, frame size
HX ..............................................................................................................................................360
8.4.16 Replacing the fan, Smart Line Module, Active Line Module, and Motor Module, frame size
JX ...............................................................................................................................................364
8.4.17 Replacing the fan, Active Interface Module, frame size FI ........................................................366
8.4.18 Replacing the fan, Active Interface Module, frame size GI........................................................368
8.4.19 Replacing the fan, Active Interface Module, frame size HI........................................................370
8.4.20 Replacing the fan, Active Interface Module, frame size JI.........................................................372
8.4.21 Replacing the fan, Basic Line Module, frame sizes FB, GB, GD...............................................374
8.4.22 Replacing the DC fuses, Smart Line Module, Active Line Module, and Motor Module,
frame size HX.............................................................................................................................376
8.4.23 Replacing the DC fuses, Smart Line Module, Active Line Module, and Motor Module,
frame size JX .............................................................................................................................378
8.4.24 Replacing the fan fuses (-F10/-F11)..........................................................................................380
8.5 Forming the DC link capacitors..................................................................................................380
A Appendix................................................................................................................................................ 385
A.1 Cable lugs ..................................................................................................................................385
A.2 List of abbreviations ...................................................................................................................386
Index...................................................................................................................................................... 391

Table of contents
Chassis power units
18 Manual, (GH3), 01/2013, 6SL3097-4AE00-0BP3