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Siemens SINAMICS G120 Hardware Installation Manual

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Hardware Installation Manual · Edition 04/2006
Power Module
PM240
SINAMICS
G120
G120
s

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Summary of Contents for Siemens SINAMICS G120

  • Page 1 Hardware Installation Manual · Edition 04/2006 Power Module PM240 SINAMICS G120 G120...
  • Page 3 Introduction Safety notes Description SINAMICS Installing/Mounting SINAMICS G120 Power Modules PM240 Operation (hardware) Technical data Hardware Installation Manual Dimension drawings Spare parts/Accessories Appendix List of abbreviations Edition 04/2006 2006-04-04 A5E00807525B AA...
  • Page 4 Trademarks All names identified by ® are registered trademarks of the Siemens AG. The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.

  • Page 5: Table Of Contents

    Documents for the SINAMICS G120 ..................1-1 Safety notes............................2-1 Description.............................. 3-1 SINAMICS G120 Power Modules - PM240 ................3-2 Power Range of SINAMICS G120 power modules PM240............3-2 Block diagram PM240........................ 3-3 Accessories for the SINAMICS G120 ..................3-4 Installing/Mounting..........................4-1 Mechanical Installation.......................
  • Page 6 SINAMICS G120 power modules PM240 .................. 3-2 Table 4-1 Distances to other equipment ....................4-1 Table 4-2 Dimensions and tightening torques of SINAMICS G120 power modules........4-3 Table 4-3 Example 1LA7060-4AB10......................4-16 Table 6-1 Distances to other equipment ....................6-1 Table 6-2 Dimensions and tightening torques of SINAMICS G120 power modules........

  • Page 7: Introduction

    Introduction Documents for the SINAMICS G120 Available documentation The following documents are available for the SINAMICS G120 inverters: • Brochure • Catalog • Getting started Guide • Operating Instructions • Hardware Installation Manual • Compact Operating Instructions (for the Control Units) •...
  • Page 8 Introduction 1.1 Documents for the SINAMICS G120 Operating Instructions The Operating Instructions gives information for the Control Unit regarding the features of the product. It gives detailed information on commissioning, control modes, system parameters, troubleshooting, technical specifications and the available options from the product.

  • Page 9: Safety Notes

    Please read the information carefully, since it is provided for your personal safety and will also help prolong the service life of your SINAMICS G120 product and the equipment to which it is connected. General...
  • Page 10 • the motor , U2, V2, W2 • and DCN, DCP/R1, R2. HP ratings are based on the Siemens 1LA motors and are given for guidance only. They do not necessarily comply with UL or NEMA HP ratings. Transport and storage...
  • Page 11 Safety notes Commissioning Warning Working on the equipment by unqualified personnel or failure to comply with warnings can result in severe personal injury or serious damage to material. Only suitably qualified personnel trained in the setup, installation, commissioning and operation of the product should carry out work on the equipment.
  • Page 12 Isolate the mains electrical supply before making or changing connections to the unit. Ensure that the SINAMICS G120 inverter is configured for the correct supply voltage – the SINAMICS G120 inverter must not be connected to a higher voltage supply.
  • Page 13 Repair Warning Repairs on equipment may only be carried out by Siemens Service, by repair centers authorized by Siemens or by authorized personnel who are thoroughly acquainted with all the warnings and operating procedures contained in this manual.
  • Page 14 Safety notes Dismantling and disposal Caution The SINAMICS G120s packaging is re-usable. Retain the packaging for future use. Easy-to-release screw and snap connectors allow you to break the unit down into its component parts. You can recycle these component parts, dispose of them in accordance with local requirements or return them to the manufacturer.

  • Page 15: Description

    Description Overview The SINAMICS G120 inverter has been designed for the accurate and efficient control of the speed and torque for three-phase motors. The SINAMICS G120 system comprises two basic modules, the Control Unit (CU) and the Power Module (PM).

  • Page 16: Sinamics G120 Power Modules - Pm240

    SINAMICS G120 Power Modules - PM240 Overview There are the following types of SINAMICS G120 power modules for different applications. • PM240 power modules with braking capability (resistive braking) – 380 V … 400 V, IP20, Frame sizes A … C unfiltered, 0,37 kW … 11 kW –...

  • Page 17: Block Diagram Pm240

    Description 3.3 Block diagram PM240 Block diagram PM240 Block diagram PM240 Figure 3-1 Power Module PM240 Power Modules PM240 Hardware Installation Manual, 2006-04-04, A5E00807525B AA...

  • Page 18: Accessories For The Sinamics G120

    Description 3.4 Accessories for the SINAMICS G120 Accessories for the SINAMICS G120 Overview The following options are available for the SINAMICS G120 Inverters: Control Unit accessories • OP (Operator Panel) • PC connection kit • MMC (Multi Media Card) • CU screening Kit Power Module accessories •...

  • Page 19: Installing/Mounting

    Distances to other equipment When mounting the SINAMICS G120 Power Modules one above the other or side by side, the specified environmental conditions must not be exceeded. Independent of this, these...
  • Page 20 Installing/Mounting 4.1 Mechanical Installation Drill patterns for SINAMICS G120 power modules FSA to FSF To allow the preliminary installation work to be undertaken, drill patterns for all the frame sizes of the SINAMICS G120 power modules are shown below. Figure 4-1...

  • Page 21: Table 4-2 Dimensions And Tightening Torques Of Sinamics G120 Power Modules

    Installing/Mounting 4.1 Mechanical Installation Table 4-2 Dimensions and tightening torques of SINAMICS G120 power modules Frame size Dimensions Height x Width x Depth (H x W x D) Fixing method Tightening torques (with CU) (without CU) 173 x 73 x 210...
  • Page 22 4.1 Mechanical Installation General rules for the environmental protection of the SINAMICS G120 Power Modules To ensure that the SINAMICS G120 Power Module is installed in the correct environmental conditions, please ensure that you adhere to the following guidelines: • The SINAMICS G120 Power Module is designed for IP20 protection only, this means: –...

  • Page 23: Electrical Installation

    Isolate the mains electrical supply before making or changing connections to the unit. Ensure that the SINAMICS G120 inverter is configured for the correct supply voltage – the SINAMICS G120 inverter must not be connected to a higher voltage supply.
  • Page 24 Installing/Mounting 4.2 Electrical Installation TN-C-S Power System Exposed Conductive Parts Figure 4-3 TN-C-S power system In a TN-C-S power system, the neutral and protective functions are combined in a single part of the system. TN-C Power System Exposed Conductive Parts Figure 4-4 TN-C power system In a TN-C power system, the neutral and protective functions are combined in a single...
  • Page 25 Installing/Mounting 4.2 Electrical Installation TT Power System Exposed Conductive Parts Figure 4-5 TT power system A TT power system has one point directly grounded, the exposed conductive parts of the installation being connected to a ground, which is electrically independent of the ground of the power system.
  • Page 26 Installing/Mounting 4.2 Electrical Installation Reforming the capacitors Following a prolonged period of storage, you must reform the capacitors in the SINAMICS G120 Power Module. The figure below shows the reforming periods required depending upon the period in storage. Figure 4-7 Timescale for reforming capacitors Power Modules PM240 Hardware Installation Manual, 2006-04-04, A5E00807525B AA...
  • Page 27 Installing/Mounting 4.2 Electrical Installation Accessing the power and motor terminals Frame sizes A … C have no terminal covers. Frame sizes D … F terminals covers are accessed by releasing the latch on the side of the terminal covers with a suitable flat-bladed screwdriver. The cover can then be pushed upwards and locked into position, as shown in the figure below.
  • Page 28 In addition, line commutation chokes reduce the effects of harmonics on the SINAMICS G120 power module and on the power supply. If the line impedance is less than 1 % (stiff supply) then a line commutation choke must be used to reduce the current peaks and to protect the SINAMICS G120 power module.
  • Page 29 For more information on chokes, please refer to the product catalog. Operation with Residual Current Devices (RCD) If an RCD (also referred to as an ELCB or a RCCB) is fitted, the SINAMICS G120 Power Module will operate without nuisance tripping provided that: •...
  • Page 30 For all frame sizes the Screen Termination Kit is supplied as an optional extra. It allows easy and efficient connection of the necessary screening. For further details on the Screen Termination Kit, please refer to the SINAMICS G120 catalog. Power Modules PM240...
  • Page 31 Installing/Mounting 4.2 Electrical Installation Screening without a Screen Termination Kit In order to meet radiated emissions a screen termiation kit must be used. Screening without a screen termination kit is only suitable for installation in a metal cabinet. Should a Screen Termination Kit not be available, then the inverter can be screened using the methodology shown in the figure below.
  • Page 32 Installing/Mounting 4.2 Electrical Installation Motor Circuit In order to ensure a straightforward, successful commissioning, it is important that the circuit connection in the motor terminal box matches the rated motor voltage entered in P0304 or the rated motor current P0305. Figure 4-12 Motor terminal box The following must be noted when entering the rating plate data or the ECD data:...
  • Page 33 Installing/Mounting 4.2 Electrical Installation configuration and equivalent circuit diagram data, then the equivalent circuit diagram data should be converted and entered corresponding to the data on the rating plate. Figure 4-13 Star/Delta configuration Note The precise equivalent circuit diagram data is of extreme importance regarding the stability of the closed-loop vector control and for the voltage boost applied to the V/f characteristic.
  • Page 34 Installing/Mounting 4.2 Electrical Installation 87 Hz characteristic When a motor with a delta circuit configuration (e.g. V , motor = 230 V) is fed from a N∆ frequency inverter, where the rated voltage corresponds to the star circuit configuration (e.g. 400 V frequency inverter), then it is important to proceed as follows and observe the following: •...
  • Page 35 Installing/Mounting 4.2 Electrical Installation Fitting the Control Unit to the Power Module The Control Unit is fitted to the Power Module as shown in the figure below. To disconnect the CU push the release button on top of the PM. The process of fitting the Control Unit to the Power Module is the same technique no matter which Control Unit or Power Module combination is required.

  • Page 37: Operation (Hardware)

    Installation conditions General rules for the environmental protection of the SINAMICS G120 Power Modules To ensure that the SINAMICS G120 Power Module is installed in the correct environmental conditions, please ensure that you adhere to the following guidelines: • The SINAMICS G120 Power Module is designed for IP20 protection only, this means: –...

  • Page 39: Technical Data

    Mechanical Data Distances to other equipment When mounting the SINAMICS G120 Power Modules one above the other or side by side, the specified environmental conditions must not be exceeded. Independent of this, these minimum distances of the SINAMICS G120 Power Modules must be observed:...
  • Page 40 Altitude If the SINAMICS G120 Power Module is to be installed at an altitude greater than 1000 m (3280 ft) derating will be required. The figure below shows the derating required in accordance with altitude.
  • Page 41 No equipment that could have a negative effect on the flow of cooling air should be installed in this area. Make sure that the cooling vents in the SINAMICS G120 Power Module are positioned correctly to allow the free movement of air.

  • Page 42: Table 6-2 Dimensions And Tightening Torques Of Sinamics G120 Power Modules

    Technical data 6.1 Mechanical Data Dimensions and tightening torques of SINAMICS G120 power modules The dimensions and tightening torques for securing the inverter are given in the table below. Table 6-2 Dimensions and tightening torques of SINAMICS G120 power modules...

  • Page 43: Electrical Data

    SINAMICS G120 inverter must not be connected to a higher voltage supply. When synchronous motors are connected or when coupling several motors in parallel, the SINAMICS G120 inverter must be operated with V/f control characteristics (P1300 = 0, 2 or Caution The control, power supply and motor cables must be laid separately.
  • Page 44 Technical data 6.2 Electrical Data Air cooling requirements Table 6-3 Air cooling requirements Frame size Required cooling air flow 10.2 24.0 51.0 54.9 116.3 54.9 116.3 2 x 54.9 2 x 116.3 150.0 317.79 Relationship between pulse frequency and current reduction Table 6-4 Current reduction depending on pulse frequency Power...

  • Page 45: Table 6-5 Data For Braking Resistors

    The input current at the rated operating point - applies for the short-circuit voltage of the line supply V = 1 % referred to the rated SINAMICS G120 Power Module power and a rated line supply voltage of 400 V without line a commutating reactor. If a line commutating reactor is used, the specified values are reduced by between 70 % and 80 %.

  • Page 46: Table 6-6 Rated Output, Input And Fuses

    Technical data 6.2 Electrical Data Table 6-6 Rated Output, Input and Fuses Product Power Frame rated output fuse Module size rated rated rated rated 3NA3…/ 400 V output input output input 3NE1… current current current current 6SL3224 Type -… unfiltered 0BE13- 0.37 803/...

  • Page 47: Table 6-7 Rated Output, Input And Fuses

    Technical data 6.2 Electrical Data Table 6-7 Rated Output, Input and Fuses Product Power Frame rated output fuse Module size rated rated rated rated 3NA3…/ 400 V output input output input 3NE1… current current current current 6SL3224 Type -… with filter class A 0BE22- 805/ 2AA0...

  • Page 48: Table 6-8 Input, Output Cable And Weight

    Technical data 6.2 Electrical Data Table 6-8 Input, Output Cable and Weight Product Power Frame Input cable Output cable weight Module size min. max. min. max. min. max. min. max. 400 V 6SL3224- … unfiltered 0BE13- 7UA0 0BE15- 5UA0 0BE17- 5UA0 0BE21- 1UA0...

  • Page 49: Table 6-9 Input, Output Cable And Weight

    Technical data 6.2 Electrical Data Table 6-9 Input, Output Cable and Weight Product Power Frame Input cable Output cable weight Module size min. max. min. max. min. max. min. max. 400 V 6SL3224- … with filter class A 0BE22- 2AA0 0BE23- 0AA0 0BE24-...
  • Page 50 Technical data 6.2 Electrical Data SINAMICS G120 Power Module Table 6-10 Performance ratings Feature Specification Line operating voltage & 3 AC 380 V … 480 V ± 10 % power ranges High Overload: 0.37 kW … 75 kW (0.50 hp … 100.0 hp) Light Overload: 2.2 kW …...
  • Page 51 50 m (164 ft) for unfiltered drives • Unscreened 100 m (328 ft) for both filtered and unfiltered drives Using output chokes as specified in the SINAMICS G120 catalog, the following cable lengths are possible: Frame size Max. permissable motor cable length for line voltage of 380 V …...

  • Page 53: Dimension Drawings

    Dimensions of the PM240 Power Module PM240 Dimension Drawings The dimension drawings for all frame sizes for the SINAMICS G120 Power Module PM240 are shown in the figures below. In combination with CU and other options please add following dimensions:...

  • Page 54: Dimensions Of The Pm240

    Dimension drawings 7.1 Dimensions of the PM240 Figure 7-1 FSA … FSC Dimensions Power Modules PM240 Hardware Installation Manual, 2006-04-04, A5E00807525B AA...
  • Page 55 Dimension drawings 7.1 Dimensions of the PM240 Figure 7-2 Frame size D (filtered) dimensions Power Modules PM240 Hardware Installation Manual, 2006-04-04, A5E00807525B AA...
  • Page 56 Dimension drawings 7.1 Dimensions of the PM240 Figure 7-3 Frame size D (unfiltered) dimensions Power Modules PM240 Hardware Installation Manual, 2006-04-04, A5E00807525B AA...
  • Page 57 Dimension drawings 7.1 Dimensions of the PM240 Figure 7-4 Frame size E (filtered) dimensions Power Modules PM240 Hardware Installation Manual, 2006-04-04, A5E00807525B AA...
  • Page 58 Dimension drawings 7.1 Dimensions of the PM240 Figure 7-5 Frame size E (unfiltered) dimensions Power Modules PM240 Hardware Installation Manual, 2006-04-04, A5E00807525B AA...
  • Page 59 Dimension drawings 7.1 Dimensions of the PM240 Figure 7-6 Frame size F (filtered) dimensions Power Modules PM240 Hardware Installation Manual, 2006-04-04, A5E00807525B AA...
  • Page 60 Dimension drawings 7.1 Dimensions of the PM240 Figure 7-7 Frame size F (unfiltered) dimensions Power Modules PM240 Hardware Installation Manual, 2006-04-04, A5E00807525B AA...

  • Page 61: Spare Parts/Accessories

    Spare parts/Accessories Replacing a Cooling Fan Replacing a Cooling Fan Frame sizes A, B and C have been designed to allow the cooling fans to be replaced. Although the various frame sizes differ in physical size and the number of fans, the replacement procedure is similar.
  • Page 62 Spare parts/Accessories 8.1 Replacing a Cooling Fan Figure 8-1 Replacing the cooling fan Power Modules PM240 Hardware Installation Manual, 2006-04-04, A5E00807525B AA...

  • Page 63: Power Module Accessories

    Power Module accessories DIN rail mounting kit The DIN rail mounting kit (DRMK) is designed to allow the SINAMICS G120 Frame Size A and B (FSA and B) inverters to be mounted on a pair of parallel DIN rails. The DRMK provides an integrated screening plate to allow for the termination of the screened motor cables and other screened cable used with the inverter.

  • Page 64: Table 8-3 Nema 1 Kit Ordering Information

    Spare parts/Accessories 8.2 Power Module accessories Table 8-3 NEMA 1 kit ordering information Description Order No. G120/S120 FSA NEMA 1 Kit 6SL3262-1CA00-0BA0 G120/S120 FSB NEMA 1 Kit 6SL3262-1CB00-0DA0 G120/S120 FSC NEMA 1 Kit 6SL3262-1CC00-0DA0 G120/S120 FSD NEMA 1 Kit 6SL3262-1CD00-0DA0 G120/S120 FSE NEMA 1 Kit 6SL3262-1CE00-0DA0 G120/S120 FSF NEMA 1 Kit...

  • Page 65: Table 8-5 Brake Module Ordering Information

    In addition, line commutation chokes reduce the effects of harmonics on the SINAMICS G120 power module and on the power supply. If the line impedance is less than 1 % (stiff supply) then a line commutation choke must be used to reduce the current peaks and to protect the SINAMICS G120 power module.
  • Page 66 8.2 Power Module accessories Braking resistor The braking resistor is designed for the SINAMICS G120 inverters with an internal brake chopper and enables loads with a large moment of inertia to be braked quickly. During braking of the motor and the load, excess energy is fed back to the inverter. This causes the voltage to rise in the DC link.

  • Page 67: Brake Control Relays

    Spare parts/Accessories 8.3 Brake Control Relays Brake Control Relays Overview There are two types of brake control relays: • Relay Brake Module • Safe Brake Module The Safe Brake Module and the Relay Brake Module are different variants of the same device (for details see option description "Brake Module Instructions".
  • Page 68 Spare parts/Accessories 8.3 Brake Control Relays Figure 8-4 Safe Brake Module Sicherheitsbremseinheit CTRL BR+) COIL Figure 8-5 Wiring of Safe Brake Module 24 V motor brakes up to a current consumption of 2 A can be operated with the Safe Brake Module.
  • Page 69 Spare parts/Accessories 8.3 Brake Control Relays Note During forced dynamisation all connections of the Safe Brake Module are checked but in operation the connection between Safe Brake Module and brake coil is not monitored. Triggering the Brake Control with non-safety Control Units The motor brake function can be activated or deactivated via P1215.

  • Page 71: Appendix

    European government organization. This approach allows the use of standards that are still in preparation. EMC Standards The SINAMICS G120 drives have been tested in accordance with the EMC Product Standard EN 61800-3:2004. Power Modules PM240 Hardware Installation Manual, 2006-04-04, A5E00807525B AA...

  • Page 72: Definition Of The Emc Environment And Categories

    Appendix A.2 Definition of the EMC Environment and Categories Definition of the EMC Environment and Categories Classification of EMC performance The EMC environment and categories are defined within the EMC Product Standard EN 61800-3, as follows: First Environment An environment that includes domestic premises and establishments that are connected directly to a public low-voltage power supply network without the use of an intermediate transformer.
  • Page 73 Compliance Table Model Remarks Category C1 - First Environment The SINAMICS G120 drives are not intended for use within the Category C1 Environment. Category C2 - First Environment - Professional Use Filtered Variants Drives FSB … FSF (400 V, 2.2 kW … 90 kW) 6SL3224-0BE**-*A*0 All units (except FSA) with integral filter.

  • Page 74: Emc Overall Performance

    Appendix A.3 EMC Overall Performance EMC Overall Performance EMC Emissions The SINAMICS G120 drives have been tested in accordance with the emission requirements of the category C2 (domestic) environment. Table A-2 Conducted & Radiated Emissions EMC Phenomenon Standard Level Conducted Emissions...
  • Page 75 Appendix A.3 EMC Overall Performance EMC Immunity The SINAMICS G120 drives have been tested in accordance with the immunity requirements of category C3 (industrial) environment: Table A-4 EMC Immunity EMC Phenomenon Standard Level Performance Criterion Electrostatic Discharge (ESD) EN 61000-4-2...

  • Page 76: Standards

    EN 60204-1 — Safety of machinery –Electrical equipment of machines European Machinery Directive The SINAMICS G120 inverter series does not fall under the scope of the Machinery Directive. However, the products have been fully evaluated for compliance with the essential Health & Safety requirements of the directive when used in a typical machine application.

  • Page 77: List Of Abbreviations

    List of abbreviations Abbreviations used with the SINAMICS G120 Products Table B-1 Abbreviations used with the SINAMICS G120 Products Abbreviations State Alternating Current Analog digital converter Address Additional frequency modification Automation Unit Analog input Request Identifier Analog output Advanced operation panel...
  • Page 78 List of abbreviations A.4 Standards Abbreviations State Commissioning, ready to run Control Unit Commissioning, run, ready to run Clockwise Digital analog converter Direct current Drive data set Digital input DIP switch Digital output Distributed I/Os DP-V1 Acyclic data transfer (extended PROFIBUS function) Drive state Equivalent circuit diagram European Economic Community...
  • Page 79 List of abbreviations A.4 Standards Abbreviations State Main actual value Human machine interface High Overload (Constant Torque) Main setpoint High-voltage transistor logic In-/output Commissioning IGBT Insulated gate bipolar transistor Sub-index Kinetic buffering Liquid crystal display Light emitting diode Length Light Overload (Variable Torque) Fiber Optic conductor LSTO Latched Safe Torque Off...
  • Page 80 List of abbreviations A.4 Standards Abbreviations State PM-IF Power module interface Parameter Number PROFIBUS Nutzerorganisation Parameter process data object Positive temperature coefficient Parameter value Pulse-width modulation Pxxxx Write parameter Process data area (Prozeßdaten) Quick commissioning Random-access memory RCCB Residual current circuit breaker Residual current device Ramp-function generator Radio frequency interference...
  • Page 81 List of abbreviations A.4 Standards Abbreviations State ZUSW Additional setpoint Power Modules PM240 Hardware Installation Manual, 2006-04-04, A5E00807525B AA...

  • Page 83: Index

    Index EMC Standards, A-1 European EMC Directive, A-6 European Low Voltage Directive, A-6 European Machinery Directive, A-6 87 Hz characteristic, 4-16 Fitting the Control Unit to the Power Module, 4-17 Accessing the power and motor terminals, 4-9 Air cooling requirements, 6-6 Altitude, 6-2 Ambient operating conditions, 6-1 Atmospheric pollution, 6-3...
  • Page 84 Index Operation with Residual Current Devices (RCD), 4-11 Technical construction file, A-1 Operation with ungrounded supplies, 4-11 Temperature, 6-1 Options for SINAMICS G120, 3-4 Tightening torques for power terminals, 6-13 Overview Control Units, 3-1 Power Modules, 3-1 UL certified Fuses, 6-7...
  • Page 86 Siemens AG Automation and Drives Standard Drives Postfach 32 69 91050 Erlangen Deutschland www.siemens.de/sinamics-g120...

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