Siemens SINAMICS G120P PM330 Operating and maintenance instructions

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SINAMICS
SINAMICS G120P
Power Module PM330
Hardware Installation Manual
Closed-loop control version V4.7 SP6
10/2016
A5E32844552B AD
Basic safety instructions
1
Introduction
2
Installing/Mounting
3
Connecting up, switching on
4
Service and maintenance
5
Technical specifications
6
Appendix
A

Siemens AG
Division Process Industries and Drives
Postfach 48 48
90026 NÜRNBERG
GERMANY
A5E32844552B AD
Ⓟ
10/2016 Subject to change
Copyright © Siemens AG 2013 - 2016.
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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Table of contents
1 Basic safety instructions.......................................................................................................................... 7
1.1 General safety instructions .......................................................................................................7
1.2 Safety instructions for electromagnetic fields (EMF) ..............................................................11
1.3 Handling electrostatic sensitive devices (ESD) ......................................................................11
1.4 Industrial security ....................................................................................................................12
1.5 Residual risks of power drive systems....................................................................................13
2 Introduction........................................................................................................................................... 15
3 Installing/Mounting ................................................................................................................................ 19
3.1 Installation conditions..............................................................................................................19
3.2 Power losses and air cooling requirements ............................................................................20
3.3 Mounting the Power Modules .................................................................................................22
3.3.1 Chassis units...........................................................................................................................25
3.4 Control Unit installation ...........................................................................................................28
4 Connecting up, switching on.................................................................................................................. 29
4.1 Cable lugs ...............................................................................................................................30
4.2 Line, motor and DC link connection........................................................................................31
4.2.1 Protective conductor ...............................................................................................................31
4.2.2 Line connection.......................................................................................................................32
4.2.3 Length of motor cables ...........................................................................................................32
4.2.4 Motor connection ....................................................................................................................33
4.2.5 Access to power and motor terminals.....................................................................................34
4.2.6 DC link connection ..................................................................................................................38
4.3 Operation on a non-grounded line supply (IT system) ...........................................................39
4.4 Installation set for line-side cable connection, left ..................................................................41
4.5 Terminal X9.............................................................................................................................47
4.6 EMC compliant connection .....................................................................................................49
4.6.1 Avoiding electromagnetic interference....................................................................................49
4.6.2 EMC-compliant cabinet design ...............................................................................................49
4.6.3 Cabinet design ........................................................................................................................50
4.6.4 Cabling....................................................................................................................................51
4.6.5 Equipotential bonding .............................................................................................................53
4.7 Switching on............................................................................................................................56

Table of contents
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5 Service and maintenance...................................................................................................................... 57
5.1 Maintenance........................................................................................................................... 57
5.2 Forming .................................................................................................................................. 59
5.3 Replacing the cooling fan....................................................................................................... 61
5.3.1 Service life of the cooling fan ................................................................................................. 61
5.3.2 Fan replacement GX.............................................................................................................. 61
5.3.3 Fan replacement for HX, JX................................................................................................... 63
6 Technical specifications ........................................................................................................................ 65
6.1 General technical data ........................................................................................................... 66
6.2 Specific technical data ........................................................................................................... 70
6.3 Derating data.......................................................................................................................... 82
6.3.1 Derating factor of the output current as a function of the operating temperature.................. 82
6.3.2 Derating as a function of the installation altitude ................................................................... 83
6.3.3 Derating factor of the output current as a function of the line voltage ................................... 84
6.3.4 Derating of the output current as a function of the pulse frequency ...................................... 85
A Appendix .............................................................................................................................................. 87
A.1 Further information on your converter ................................................................................... 87
A.1.1 Manuals for your inverter ....................................................................................................... 87
A.1.2 Configuring support................................................................................................................ 88
A.1.3 Product Support ..................................................................................................................... 88
A.1.4 Certificates ............................................................................................................................. 89
A.2 Electromagnetic compatibility ................................................................................................ 89
A.2.1 Definition of the EMC Environment and Categories .............................................................. 89
A.2.2 Compliance with EMC Environment and Categories............................................................. 90
A.2.3 EMC limit values in South Korea ........................................................................................... 92
A.3 Abbreviations ......................................................................................................................... 93
Index .................................................................................................................................................... 95

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Basic safety instructions
1
1.1
General safety instructions
DANGER
Danger to life due to live parts and other energy sources
Touching live parts can result in death or severe injury.
•Only work on electrical equipment if you are appropriately qualified.
•Always observe the country-specific safety rules for all work.
Generally, six steps apply when establishing safety:
1. Prepare for shutdown and notify all those who will be affected by the procedure.
2. Disconnect the machine from the supply.
–Switch off the machine.
–Wait until the discharge time specified on the warning labels has elapsed.
–Check that it really is in a zero-voltage state, from phase conductor to phase
conductor and phase conductor to protective conductor.
–Check that every auxiliary circuit is de-energized.
–Ensure that the motors cannot move.
3. Identify all other dangerous energy sources, e.g. compressed air, hydraulic systems, or
water.
4. Isolate or neutralize all hazardous energy sources by closing switches, grounding or
short-circuiting or closing valves, for example.
5. Take measures to prevent reconnection of the energy sources.
6. Ensure that the correct machine is completely interlocked.
After you have completed the work, restore the operational readiness by following the
above steps in the reverse order.
WARNING
Danger to life through a hazardous voltage when connecting an unsuitable power supply
In the event of a fault, touching live parts can result in death or severe injury.
•Only use power supplies that provide SELV (Safety Extra Low Voltage) or PELV
(Protective Extra Low Voltage) output voltages for all connections and terminals of the
electronics modules.

Basic safety instructions
1.1 General safety instructions
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WARNING
Danger to life when live parts are touched on damaged devices
Improper handling of devices can cause damage.
For damaged devices, hazardous voltages can be present at the enclosure or at exposed
components; if touched, this can result in death or severe injury.
•Ensure compliance with the limit values specified in the technical data during transport,
storage and operation.
•Do not use any damaged devices.
WARNING
Danger to life through electric shock due to unconnected cable shields
Hazardous touch voltages can occur through capacitive cross-coupling due to unconnected
cable shields.
•Connect cable shields and unused conductors of power cables (e.g. brake conductors)
at least on one side to the grounded housing potential.
WARNING
Danger to life due to electric shock when not grounded
For missing or incorrectly implemented protective conductor connection for devices with
protection class I, high voltages can be present at open, exposed parts, which when
touched, can result in death or severe injury.
•Ground the device in compliance with the applicable regulations.
WARNING
Danger to life due to electric shock when opening plug connections in operation
When opening plug connections in operation, arcs can result in severe injury or death.
•Only open plug connections when the equipment is in a voltage-free state, unless it has
been explicitly stated that they can be opened in operation.
NOTICE
Material damage due to loose power connections
Insufficient tightening torques or vibrations can result in loose electrical connections. This
can result in damage due to fire, device defects, or malfunctions.
•Tighten all power connections with the specified tightening torques, e.g. line connection,
motor connection, DC link connections.
•Check all power connections at regular intervals. This applies in particular after
transport.

Basic safety instructions
1.1 General safety instructions
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WARNING
Danger to life due to fire spreading if housing is inadequate
Fire and smoke development can cause severe personal injury or material damage.
•Install devices without a protective enclosure in a metal control cabinet (or protect the
device by another equivalent measure) in such a way that contact with fire is prevented.
•Ensure that smoke can only escape via controlled and monitored paths.
WARNING
Danger to life through unexpected movement of machines when using mobile wireless
devices or mobile phones
Using mobile radios or mobile phones with a transmit power > 1 W closer than approx. 2 m
to the components may cause the devices to malfunction, influence the functional safety of
machines therefore putting people at risk or causing material damage.
•When close to components, switch off all wireless devices and mobile phones.
WARNING
Danger to life due to the motor catching fire in the event of insulation overload
There is a greater load on the motor insulation through a ground fault in an IT system. If the
insulation fails, it is possible that death or severe injury can occur as a result of smoke and
fire.
•Use a monitoring device that signals an insulation fault.
•Correct the fault as quickly as possible so the motor insulation is not overloaded.
WARNING
Danger to life due to fire if overheating occurs because of insufficient ventilation clearances
Inadequate ventilation clearances can cause overheating of components with subsequent
fire and smoke. This can cause severe injury or even death. This can also result in
increased downtime and reduced service lives for devices/systems.
•Ensure compliance with the specified minimum clearance as ventilation clearance for
the respective component.

Basic safety instructions
1.1 General safety instructions
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WARNING
Danger of an accident occurring due to missing or illegible warning labels
Missing or illegible warning labels can result in accidents involving death or serious injury.
•Check that the warning labels are complete based on the documentation.
•Attach any missing warning labels to the components, in the national language if
necessary.
•Replace illegible warning labels.
NOTICE
Device damage caused by incorrect voltage/insulation tests
Incorrect voltage/insulation tests can damage the device.
•Before carrying out a voltage/insulation check of the system/machine, disconnect the
devices as all converters and motors have been subject to a high voltage test by the
manufacturer, and therefore it is not necessary to perform an additional test within the
system/machine.
WARNING
Danger to life due to inactive safety functions
Inactive or non-adapted safety functions can trigger machine malfunctions that can cause
serious injury or death.
•Observe the information in the appropriate product documentation before
commissioning.
•Carry out a safety inspection for functions relevant to safety on the entire system,
including all safety-related components.
•Ensure that the safety functions used in your drives and automation tasks are adjusted
and activated through appropriate parameterizing.
•Perform a function test.
•Only put your plant into productive operation once you have absolutely guaranteed that
the functions relevant to safety are operating correctly.

Basic safety instructions
1.2 Safety instructions for electromagnetic fields (EMF)
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1.2
Safety instructions for electromagnetic fields (EMF)
WARNING
Danger to life from electromagnetic fields
Electromagnetic fields (EMF) are generated by the operation of electrical power equipment
such as transformers, converters or motors.
People with pacemakers or implants are at a special risk in the immediate vicinity of these
devices/systems.
•Ensure that the persons involved are the necessary distance away (minimum 2 m).
1.3
Handling electrostatic sensitive devices (ESD)
Electrostatic sensitive devices (ESDs) are individual components, integrated circuits,
modules or devices that may be damaged by either electrostatic fields or electrostatic
discharge.
NOTICE
Damage caused by electric fields or electrostatic discharge
Electric fields or electrostatic discharge can result in malfunctions as a result of damaged
individual parts, integrated circuits, modules or devices.
•Only pack, store, transport and send electronic components, modules or devices in their
original packaging or in other suitable materials, e.g conductive foam rubber of
aluminum foil.
•Only touch components, modules and devices if you are first grounded by applying one
of the following measures:
–Wearing an ESD wrist strap
–Wearing ESD shoes or ESD grounding straps in ESD areas with conductive flooring
•Only place electronic components, modules or devices on conductive surfaces (table
with ESD surface, conductive ESD foam, ESD packaging, ESD transport container).

Basic safety instructions
1.4 Industrial security
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1.4
Industrial security
Note
Industrial security
Siemens provides products and solutions with industrial security functions that support the
secure operation of plants, systems, machines and networ
ks.
In order to protect plants, systems, machines and networks against cyber threats, it is
necessary to implement
– and continuously maintain – a holistic, state-of-the-art industrial
security concept. Siemens products and solutions only represent one com
ponent of such a
concept.
The customer is responsible for preventing unauthorized access to its plants, systems,
machines and networks. Systems, machines and components should only be connected to
the enterprise network or the internet if and to the extent
necessary and with appropriate
security measures (e.g. use of firewalls and network segmentation) in place.
Additionally, Siemens’ guidance on appropriate security measures should be taken into
account. For more information about industrial security, ple
ase visit:
Industrial security (
http://www.siemens.com/industrialsecurity).
Siemens’ products and solutions undergo continuous development to make them more
secure. Siemens strongly recommends to
apply product updates as soon as available and to
always use the latest product versions. Use of product versions that are no longer supported,
and failure to apply latest updates may increase customer’s exposure to cyber threats.
To stay informed about p
roduct updates, subscribe to the Siemens Industrial Security RSS
Feed at:
Industrial security (http://www.siemens.com/industrialsecurity).
WARNING
Danger to life as a result of unsafe operating states resulting from software manipulation
Software manipulations (e.g. viruses, trojans, malware or worms) can cause unsafe
operating states in your system that may lead to death, serious injury, and property
damage.
•Keep the software up to date.
•Incorporate the automation and drive components into a state-of-the-art, integrated
industrial security concept for the installation or machine.
•Make sure that you include all installed products into the integrated industrial security
concept.
•Protect files stored on exchangeable storage media from malicious software by with
suitable protection measures, e.g. virus scanners.
Note
Industrial security Configuration Manual
You can find a Configuration Manual on the topic of industrial security at this address
(
https://support.industry.siemens.com/cs/ww/en/view/108862708).

Basic safety instructions
1.5 Residual risks of power drive systems
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1.5
Residual risks of power drive systems
When assessing the machine- or system-related risk in accordance with the respective local
regulations (e.g. EC Machinery Directive), the machine manufacturer or system installer
must take into account the following residual risks emanating from the control and drive
components of a drive system:
1. Uncontrolled motion of the driven machine or system components during commissioning,
operation, maintenance and repair caused by, for example:
–Hardware and/or software errors in the sensors, control system, actuators and cables
and connections
–Response times of the controller and drive
–Operation and/or environmental conditions outside the specification
–Condensation/conductive pollution
–Parameterization, programming, cabling, and installation errors
–Use of wireless devices/mobile phones in the immediate vicinity of electronic
components
–External influence/damage
–X-ray, ionizing radiation and cosmic radiation
2. Unusually high temperatures - including open flames - as well as the emission of light,
noise, particles, gases, etc. can occur inside and outside the components under fault
conditions caused by, for example:
–Component malfunctions
–Software errors
–Operation and/or environmental conditions outside the specification
–External influence/damage
3. Hazardous shock voltages caused by, for example:
–Component malfunctions
–Influence of electrostatic charging
–Induction of voltages in moving motors
–Operation and/or environmental conditions outside the specification
–Condensation/conductive pollution
–External influence/damage
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
6. Influence of network-connected communication systems, e.g. ripple-control transmitters
or data communication via the network
For more information about the residual risks of the drive system components, see the
relevant sections in the technical user documentation.

Basic safety instructions
1.5 Residual risks of power drive systems
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Power Module PM330
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Introduction
2
Power Module - PM330
The PM330 Power Module is a part of the modular family of SINAMICS G120 converters.
PM330 Power Modules have been specifically optimized for driving pumps, fans, blowers
and compressors with square-law load characteristic for use in HVAC applications. The
Power Module is available with the "internal air cooling" cooling method.
The Power Modules are available for the following rated voltages and rated powers:
●3 AC 380 V … 480 V: 160 kW … 560 kW
●3 AC 500 V … 690 V: 315 kW … 630 kW
The Power Modules can be connected to the following line supply systems:
●TN system
●TT system
●IT system
690-V line supplies with grounded line conductor are not permitted.
As standard, a line reactor (uk≥ 2 %) must be provided at the line input (see the following
diagram).

Introduction
Power Module PM330
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Figure 2-1 PM330 block diagram

Introduction
Power Module PM330
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Note
Principle of the precharging circuit
SINAMICS PM330 Power Modules include a half
-controlled thyristor bridge as rectifier
circuit. As a result of the precharging principle with phase control, precharging is only started
when all of the enable signals are available and by setting the ON/OFF co
mmand
(p0840
= 1).
The DC link is then fully charged after approximately 400
ms.
The Power Modules can be used with the following Control Units, including all
communication versions with firmware version from 4.6 HF7 and higher.
•
CU230P-2 PN
6SL3243
-0BB30-1FAx
•
CU230P-2 DP
6SL3243
-0BB30-1PAx
•
CU230P-2 HVAC
6SL3243
-0BB30-1HAx
Operation with Control Units other than those listed above is not permitted.

Introduction
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Power Module PM330
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Installing/Mounting
3
3.1
Installation conditions
Unpacking and disposal
Note
The c
onverter packaging can be reused.
The individual components of the packaging can be recycled or disposed of in compliance
with local regulations.
General rules for protecting Power Modules against environmental effects
To ensure that the Power Module is installed in the correct environmental conditions, please
make sure that you adhere to the following guidelines:
●The Power Modules are designed:
–to be installed in an electrical cabinet
–with protection against the ingress of solid foreign objects ≥ 12.5 mm
–without protection against the ingress of water
●Furthermore, observe the following conditions:
–Ensure that the device is free of dust and dirt.
(when using a vacuum cleaner, this must comply with ESD equipment rules)
–Keep the device away from water, solvents and chemicals.
Take care to install it away from potential water hazards, for example, do not install it
beneath pipes that are subject to condensation. Avoid installing it where excessive
humidity and condensation may occur.
–Keep it within the maximum and minimum operating temperatures.
–Ensure that the correct level of ventilation and air flow is provided.
–Fast temperature changes of the air drawn in (e.g. by using cooling units) are not
permitted due to the danger of condensation. Condensation is not permissible when
switching on.
–Ensure that all Power Modules and the cabinet are grounded according to the
guidelines given in this chapter (see Chapter Connecting up, switching on (Page 29)).
It is only permissible that the Power Module is installed in a vertical position.

Installing/Mounting
3.2 Power losses and air cooling requirements
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WARNING
Danger to life due to voltage
To ensure safe operation of the equipment, it must be installed and commissioned by
qualified personnel in full compliance with the warnings laid down in this manual.
It is especially important to comply with general and local installation and safety regulations
for working on plants and systems with hazardous voltages (e.g. EN 61800-5-1) - as well as
the relevant regulations regarding the correct use of tools and personal protective
equipment (PPE).
Protection against the spread of fire
The device may only be operated in closed housings or in control cabinets with protective
covers that are closed, and when all of the protective devices are used. The installation of
the device in a metal control cabinet or the protection with another equivalent measure must
prevent the spread of fire and emissions outside the control cabinet.
Protection against condensation or electrically conductive pollution
Protect the device, e.g. by installing it in a control cabinet with degree of protection IP54
according to IEC 60529 or NEMA 12. Further measures may be necessary for particularly
critical operating conditions.
If condensation or conductive pollution can be excluded at the installation site, a lower
degree of control cabinet protection is permitted.
3.2
Power losses and air cooling requirements
General requirement
Installation in the cabinet and the cooling must guarantee that the air temperature - under all
operating conditions and all possible cabinet equipment configurations - inside the Power
Module at the top in the area of the rectifier modules is a maximum of 65 °C - and the air
intake below the Control Unit (behind the left hand housing flap) is a maximum of 60 °C.