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
Power Module PM330
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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
Power Module PM330
10 Hardware Installation Manual, 10/2016, A5E32844552B AD
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.