Siemens Model 240 Installation manual

Hardware Installation Manual · Edition 04/2006
Power Module
PM240
SINAMICS
G120
s
Introduction
1
Safety notes
2
SINAMICS
Description
3
SINAMICS G120
Power Modules PM240
Installing/Mounting
4
Operation (hardware)
5
Technical data
6
Dimension drawings
7
Spare parts/Accessories
8
Appendix
A
List of abbreviations
B
Hardware Installation Manual
Edition 04/2006
2006-04-04
A5E00807525B AA
Safety Guidelines
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
with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.
Caution
without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.
Notice
indicates that an unintended result or situation can occur if the corresponding information is not taken into
account.
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 device/system may only be set up and used in conjunction with this documentation. Commissioning and
operation of a device/system may only be performed by qualified personnel. Within the context of the safety notes
in this documentation qualified persons are defined as persons who are authorized to commission, ground and
label devices, systems and circuits in accordance with established safety practices and standards.
Prescribed Usage
Note the following:
Warning
This device may only be used for the applications described in the catalog or the technical description and only in
connection with devices or components from other manufacturers which have been approved or recommended by
Siemens. Correct, reliable operation of the product requires proper transport, storage, positioning and assembly
as well as careful operation and maintenance.
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.
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.
Siemens AG
Automation and Drives
Postfach 48 48
90437 NÜRNBERG
GERMANY
Order No.: A5E00807525B AA
Edition 04/2006
Copyright © Siemens AG 2006.
Technical data subject to change
Table of contents
1
Introduction............................................................................................................................................. 1-1
1.1
Documents for the SINAMICS G120 ......................................................................................... 1-1
2
Safety notes............................................................................................................................................ 2-1
3
Description.............................................................................................................................................. 3-1
4
5
3.1
SINAMICS G120 Power Modules - PM240 ............................................................................... 3-2
3.2
Power Range of SINAMICS G120 power modules PM240....................................................... 3-2
3.3
Block diagram PM240................................................................................................................ 3-3
3.4
Accessories for the SINAMICS G120 ........................................................................................ 3-4
Installing/Mounting.................................................................................................................................. 4-1
4.1
Mechanical Installation............................................................................................................... 4-1
4.2
Electrical Installation .................................................................................................................. 4-5
Operation (hardware).............................................................................................................................. 5-1
5.1
6
7
Technical data ........................................................................................................................................ 6-1
6.1
Mechanical Data ........................................................................................................................ 6-1
6.2
Electrical Data ............................................................................................................................ 6-5
Dimension drawings ............................................................................................................................... 7-1
7.1
8
A
B
Installation conditions................................................................................................................. 5-1
Dimensions of the PM240.......................................................................................................... 7-1
Spare parts/Accessories......................................................................................................................... 8-1
8.1
Replacing a Cooling Fan............................................................................................................ 8-1
8.2
Power Module accessories ........................................................................................................ 8-3
8.3
Brake Control Relays ................................................................................................................. 8-7
Appendix.................................................................................................................................................A-1
A.1
Electromagnetic Compatibility.................................................................................................... A-1
A.2
Definition of the EMC Environment and Categories .................................................................. A-2
A.3
EMC Overall Performance ......................................................................................................... A-4
A.4
Standards................................................................................................................................... A-6
List of abbreviations................................................................................................................................B-1
Index................................................................................................................................................ Index-1
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
iii
Table of contents
Tables
Table 3-1
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.................................. 6-4
Table 6-3
Air cooling requirements ............................................................................................................ 6-6
Table 6-4
Current reduction depending on pulse frequency...................................................................... 6-6
Table 6-5
Data for braking resistors ........................................................................................................... 6-7
Table 6-6
Rated Output, Input and Fuses.................................................................................................. 6-8
Table 6-7
Rated Output, Input and Fuses.................................................................................................. 6-9
Table 6-8
Input, Output Cable and Weight............................................................................................... 6-10
Table 6-9
Input, Output Cable and Weight............................................................................................... 6-11
Table 6-10
Performance ratings................................................................................................................. 6-12
Table 6-11
Power terminals - tightening torques ....................................................................................... 6-13
Table 7-1
Additional dimensions ................................................................................................................ 7-1
Table 8-1
DIN rail pitch............................................................................................................................... 8-3
Table 8-2
DIN rail mounting kit ordering information.................................................................................. 8-3
Table 8-3
NEMA 1 kit ordering information ................................................................................................ 8-4
Table 8-4
Screen termination kit ordering information ............................................................................... 8-4
Table 8-5
Brake module ordering information............................................................................................ 8-5
Table 8-6
Choke and filter ordering information......................................................................................... 8-5
Table 8-7
Braking resistor ordering information ......................................................................................... 8-6
Table A-1
Compliance Table ......................................................................................................................A-3
Table A-2
Conducted & Radiated Emissions .............................................................................................A-4
Table A-3
Harmonic Currents .....................................................................................................................A-4
Table A-4
EMC Immunity............................................................................................................................A-5
Table B-1
Abbreviations used with the SINAMICS G120 Products ...........................................................B-1
iv
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
Introduction
1.1
1
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)
• Parameter List.
The documents can be downloaded from the Internet via the following link:
http://www.siemens.de/sinamics-g120
Description of the documents
Brochure
The brochure is advertising literature designed to introduce the product to the marketplace. It
contains a basic outline of the product with a brief overview of the technical capabilities of
the product.
Catalog
The catalog presents information that allows the customer to select an appropriate inverter
including all available options. It contains detailed technical specifications, ordering and
pricing information to allow the customer to order the appropriate items for their application
or plant.
Getting started Guide
The Getting started Guide presents warnings, dimension drawings and a brief set up
information for the customer.
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
1-1
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.
Hardware Installation Manual
The Hardware Installation Manual gives information for the Power Modules regarding the
features of the product. It gives detailed information on installation, technical specifications,
dimension drawings and the available options from the product.
Compact Operating Instructions
The Compact Operating Instructions gives a brief description of the installation,
commissioning and control modes as well as an overview of troubleshooting, technical
specifications and the available options from the product.
Parameter List
The Parameter List contains a detailed description of all the parameters that can be modified
and adapted for specific applications. The Parameter List also contains a series of function
diagrams to diagramatically portray the nature and interoperability of the system parameters.
1-2
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
Safety notes
2
Safety Instructions
The following Warnings, Cautions and Notes are provided for your safety and as a means of
preventing damage to the product or components in the connected machines. This section
lists Warnings, Cautions and Notes, which apply generally when handling the SINAMICS
G120 product, classified as General, Transport and Storage, Commissioning, Operation,
Repair and Dismantling and Disposal.
Specific Warnings, Cautions and Notes that apply to particular activities are listed at the
beginning of the relevant sections in this manual and are repeated or supplemented at
critical points throughout these sections.
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
Caution
Children and the general public must be prevented from accessing or approaching the
equipment!
This equipment may only be used for the purpose specified by the manufacturer.
Unauthorized modifications and the use of spare parts and accessories that are not sold or
recommended by the manufacturer of the equipment can cause fires, electric shocks and
injuries.
Notice
Keep these operating instructions within easy reach of the equipment and make them
available to all users.
Whenever measuring or testing has to be performed on live equipment, the regulations of
Safety Code BGV A2 must be observed, in particular § 8 "Permissible Deviations when
Working on Live Parts". Suitable electronic tools should be used.
Before installing and commissioning, please read these safety instructions and warnings
carefully and all the warning labels attached to the equipment. Make sure that the warning
labels are kept in a legible condition and replace missing or damaged labels.
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
2-1
Safety notes
Risk of electric shock
Warning
This equipment contains dangerous voltages and controls potentially dangerous rotating
mechanical parts. Non-compliance with the Warnings or failure to follow the instructions
contained in this manual can result in loss of life, severe personal injury or serious damage
to property.
Only suitable qualified personnel should work on this equipment, and only after becoming
familiar with all safety notices, installation, operation and maintenance procedures contained
in this manual. The successful and safe operation of this equipment is dependent upon ist
proper handling, installation, operation and maintenance.
Take particular notice of the general and regional installation and safety regulations
regarding work on dangerous voltage installation (e.g. EN 50178) as well as the relevant
regulations regarding the correct use of tools and personal protective equipment (PPE).
Risk of electric shock
The line input, DC and motor terminals can carry dangerous voltages even if the SINAMICS
G120 inverter is inoperative. Wait five minutes to allow the unit to discharge after switching
off the line supply before carrying out any installation work.
The terminals can carry dangerous voltages, even after the inverter has become inoperative.
Depending on the frame size the following terminals are for:
• the power supply L/U1/L1, N/V1/L2 and W1/L3
• 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
Warning
Correct transport, storage as well as careful operation and maintenance are essential for the
proper and safe operation of the equipment.
Caution
Protect the equipment against physical shocks and vibration during transport and storage. It
is important that the equipment is protected from water (rainfall) and excessive
temperatures.
2-2
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
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.
Caution
The control cables must be laid separately from the power cables. Carry out the connections
as shown in the installation section in this manual, to prevent inductive and capacitive
interference from affecting the correct function of the system.
Mechanical installation
Warning
To ensure the 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.
Take particular note of the general and regional installation and safety regulations regarding
work on dangerous voltage installation (e.g. EN 61800-5-1) as well as the relevant
regulations regarding the correct use of tools and personal protective equipment (PPE).
The line input, DC and motor terminals can carry dangerous voltages even if the SINAMICS
G120 inverter is inoperative. Wait 5 minutes to allow the unit to discharge after switching off
the line supply before carrying out any installation work.
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
2-3
Safety notes
Electrical installation
Warning
Power and motor connections
The SINAMICS G120 inverter must always be grounded. If the SINAMICS G120 inverter is
not grounded correctly, extremely dangerous conditions may arise which could prove
potentially fatal.
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.
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
3).
Note
TT-/IT power systems can only be used with unfiltered drives.
Caution
Cables
The control cables must be laid separately from the power cables. The connection must be
carried out as shown in the installation section in this manual, to prevent inductive and
capacitive interference from affecting the correct function of the system.
2-4
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
Safety notes
Operation
Warning
The SINAMICS G120 inverters operate at high voltages.
When operating electrical devices, it is impossible to avoid applying hazardous voltages to
certain parts of the equipment.
Emergency Stop facilities according to EN 60204, IEC 204 (VDE 0113) must remain
operative in all operating modes of the control equipment. Any disengagement of the
Emergency Stop facility must not lead to an uncontrolled or an undefined restart of the
equipment.
Certain parameter settings may cause the SINAMICS G120 inverter to restart automatically
after an input power failure, for example, the automatic restart function.
Wherever faults occurring in the control equipment can lead to substantial material damage
or even grievous bodily injury (that is, potentially dangerous faults), additional external
precautions must be taken or facilities provided to ensure or enforce safe operation, even
when a fault occurs (e.g. independent limit switches, mechanical interlocks, etc.).
Motor parameters must be accurately configured for motor overload protection to operate
correctly.
This equipment is capable of providing internal motor overload protection according to
UL508C. Refer to P0610 and P0335, i2t is ON by default.
This equipment is suitable for use in a circuit capable of delivering not more than 10,000
symmetrical amperes (rms), for a maximum voltage of 460 V when protected by an H, J or K
type fuse, a circuit breaker or self-protected combination motor controller.
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.
Any defective parts or components must be replaced using parts contained in the relevant
spare parts list.
Disconnect the power supply before opening the equipment for access.
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
2-5
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.
2-6
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
3
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).
Control Units
• CU240S
Control Unit for operation via terminals
• CU240S DP
Control Unit for operation via terminals or PROFIBUS DP Communication
• CU240S DP-F
Control Unit with fail-safe functions for operation via terminals or PROFIBUS DP
Communication (PROFIsafe).
Power Modules
• PM240 400 V, IP20
– Frame sizes A unfiltered
– Frame sizes B … F unfiltered or with filter Class A.
PM240 power modules can be used for control units with and without fail-safe funtions.
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
3-1
Description
3.1 SINAMICS G120 Power Modules - PM240
3.1
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
– 380 V … 400 V, IP20, Frame sizes D … F unfiltered, 15 kW … 75 kW
– 380 V … 400 V, IP20, Frame sizes B … F unfiltered or filter Class A, 2,2 kW … 11 kW
– 380 V … 400 V, IP20, Frame sizes D … F unfiltered or filter Class A, 15 kW … 75 kW.
3.2
Power Range of SINAMICS G120 power modules PM240
Power range of SINAMICS G120 power modules PM240
Table 3-1
SINAMICS G120 power modules PM240
Power Module
PM240 FSA
3-2
Power Rating
Power Rating
Voltage
kW
Hp
V
Filtered
Unfiltered
0.37 … 1.5
0.5 … 2.0
380 … 400
--
✓
PM240 FSB
2.2 … 4.0
3.0 … 5.0
380 … 400
✓
✓
PM240 FSC
5.5 … 11.0
7.5 … 15.0
380 … 400
✓
✓
PM240 FSD
15.0 … 22.0
20.0 … 30.0
380 … 400
✓
✓
PM240 FSE
30.0 … 37.0
40.0 … 50.0
380 … 400
✓
✓
PM240 FSF
45.0 … 75.0
60.0 … 100.0
380 … 400
✓
✓
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
Description
3.3 Block diagram PM240
3.3
Block diagram PM240
Block diagram PM240
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/
/
3(
6,
8 9 :
/ / /
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30
a
'&35
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&38
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Figure 3-1
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Power Module PM240
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
3-3
Description
3.4 Accessories for the SINAMICS G120
3.4
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
• DIN rail mounting kit
• NEMA 1 kit
• Screen termination kit
• Brake and Safe brake modules
• Chokes
• Filters
• Braking resistor.
Power Module spare parts
• Fan.
A description of the individual options, there purposes and ordering information is given in
the SINAMICS G120 catalog.
3-4
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
4
Installing/Mounting
Overwiew
This section gives an overview about the installation of the SINAMISCS G120 Power
Modules. For technical details please refer to "Technical Data".
4.1
Mechanical Installation
Mechanical installation
Warning
To ensure the 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.
Take particular note of the general and regional installation and safety regulations regarding
work on dangerous voltage installation (e.g. EN 61800-5-1) as well as the relevant
regulations regarding the correct use of tools and personal protective equipment (PPE).
The line input, DC and motor terminals can carry dangerous voltages even if the SINAMICS
G120 inverter is inoperative. Wait 5 minutes to allow the unit to discharge after switching off
the line supply before carrying out any installation work.
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:
Table 4-1
Distances to other equipment
Frame A
Size
mm
B
C
D
E
F
inch
mm
inch
mm
inch
mm
inch
mm
inch
mm
inch
Side
by
Side
30
1.18
40
1.57
50
1.96
0
0
0
0
0
0
Above
and
Below
100
3.93
100
3.93
125
4.92
300
11.81
300
11.81
350
13.77
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
4-1
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.
PP
PP
PP
š
š
PP
PP
)6$
PP
PP
š
)6%
PP
PP
)6&
PP
PP
PP
šPP
šPP
šPP
PP
PP
PP
)6'8QILOWHUHG
)6')LOWHUHG
PP
PP
PP
šPP
PP
PP
)6(8QILOWHUHG
PP
šPP
PP
šPP
PP
PP
)6()LOWHUHG
)6)8QILOWHUHG
)6))LOWHUHG
Figure 4-1
Drill patterns for SINAMICS G120 power modules FSA to FSF
Dimensions and tightening torques of SINAMICS G120 power modules
The dimensions and tightening torques for securing the inverter are given in the table below.
4-2
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
Installing/Mounting
4.1 Mechanical Installation
Table 4-2
Frame size
A
B
C
D
Unfiltered
D
Filtered
E
Unfiltered
E
Filtered
F
Unfiltered
F
Filtered
Dimensions and tightening torques of SINAMICS G120 power modules
Dimensions
Height x Width x Depth (H x W x D)
(with CU)
(without CU)
mm
173 x 73 x 210
173 x 73 x 145
inch
6.81 x 2.87 x 8.27
6.81 x 2.87 x 5.71
mm
270 x 153 x 230
270 x 153 x 165
inch
10.63 x 6.02 x 9.05
10.63 x 6.02 x 6.50
mm
334 x 189 x 250
334 x 189 x 185
inch
13.1 x 7.41 x 9.84
13.1 x 7.41 x 7.28
mm
419 x 275 x 260
419 x 275 x 204
inch
16.3 x 10.8 x 10.2
16.3 x 10.8 x 8.0
mm
512 x 275 x 260
512 x 275 x 204
inch
20.1 x 10.8 x 10.2
20.1 x 10.8 x 8.0
mm
499 x 275 x 260
499 x 275 x 204
inch
19.6 x 10.8 x 10.2
19.6 x 10.8 x 8.0
mm
635 x 275 x 260
635 x 275 x 204
inch
25.0 x 10.8 x 10.2
25.0 x 10.8 x 8.0
mm
635 x 350 x 372
635 x 350 x 316
inch
25.0 x 13.8 x 14.6
25.0 x 13.8 x 12.4
mm
934 x 350 x 372
934 x 350 x 316
inch
36.8 x 13.8 x 14.6
36.8 x 13.8 x 12.4
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
Fixing method
Tightening
torques
2 x M4 bolts,
2 x M4 nuts,
2 x M4 washers
2.5 Nm
(22.1 lbf.in)
with washers
fitted.
4 x M4 bolts,
4 x M4 nuts,
4 x M4 washers
4 x M5 bolts,
4 x M5 nuts,
4 x M5 washers
4 x M6 bolts,
4 x M6 nuts,
4 x M6 washers
6 Nm
(53 lbf.in) with
washers fitted.
4 x M8 bolts,
4 x M8 nuts,
4 x M8 washers
13 Nm
(115 lbf.in) with
washers fitted.
4-3
Installing/Mounting
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:
– It is protected from the ingress of solid foreign objects ≥ 12.5 mm (0.49 inches).
– It is designed to not allow access to hazardous parts with a finger.
– It is not protected against the ingress of water.
• Keep the SINAMICS G120 Power Module free from dust and dirt.
• Keep the SINAMICS G120 Power Module away from water, solvents and chemicals.
• Keep the SINAMICS G120 Power Module within the maximum and minimum operating
temperatures.
• Ensure that the correct level of ventilation and air flow is provided.
• Ensure that good earthing/grounding practices are followed for each SINAMICS G120
Power Module and the cabinet.
Permissable Cable Length
All inverters will operate at full specification with cable lengths as follows:
• Screened
25 m (82 ft) for filtered drives
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
4-4
Max. permissable motor cable length for line voltage of
380 V … 400 V ± 10 %
400 V … 480 V ± 10 %
shielded
unshielded
shielded
unshielded
A
150 m
150 m
100 m
100 m
B…C
150 m
225 m
100 m
150 m
D…F
200 m
300 m
200 m
300 m
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
Installing/Mounting
4.2 Electrical Installation
4.2
Electrical Installation
Electrical installation
Warning
Power and motor connections
The SINAMICS G120 inverter must always be grounded. If the SINAMICS G120 inverter is
not grounded correctly, extremely dangerous conditions may arise which could prove
potentially fatal.
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.
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
3).
Power Distribution Systems
The power distribution systems described below, as defined in EN 60950, have been
considered in the design of the inverter. In the next figures three phase systems are outlined.
The PM240 three phase inverter must be connected to L1, L2 and L3. PE must always be
connected. The PM240 will operate with most supply systems. In an IT Grid an output
ground failure will lead to trip of the drive overload protection.
TN-S Power System
L1
L2
L3
N
PE
L1
L2
L3
Exposed Conductive Parts
Figure 4-2
TN-S power system
A TN-S power system has separate neutral and protective ground conductors throughout the
system.
This type of power system is the standard distribution system in the UK.
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
4-5
Installing/Mounting
4.2 Electrical Installation
TN-C-S Power System
L1
L2
L3
N
PE
PEN
L1
L2
L3
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
L1
L2
L3
PEN
L1
L2
L3
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
conductor throughout the system.
4-6
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
Installing/Mounting
4.2 Electrical Installation
TT Power System
L1
L2
L3
N
PE
L1
L2
L3
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.
IT Power System
L1
L2
L3
N
PE
L1
L2
L3
Exposed Conductive Parts
Figure 4-6
IT power system
An IT power system has no direct connection to ground - instead the exposed parts of the
electrical installation are grounded.
It will be necessary to provide a mechanism for disconnecting the "DC link midpoint to
ground" capacitor.
Note
TT-/IT power systems can only be used with unfiltered drives.
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
4-7
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.
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Figure 4-7
4-8
Timescale for reforming capacitors
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
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.
Figure 4-8
Access the power and motor terminals on FSD … FSF
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
4-9
Installing/Mounting
4.2 Electrical Installation
Power and motor terminal layout
Terminals not usually utilised for Frame size A … C are protected by a feature integral to the
plastic housing. If access to the terminal is required, the two upper plastic protectors can be
removed using a suitable pair of pliers. Ensure that no plastics from the protectors fall into
the inverter housing.
The figure below shows the layout of the power and motor terminals of the PM240 Frame
Sizes A … F. The figure also includes the tightening torques for the terminals.
FSA: 1.1 Nm/9.7 lbf.in
FSB: 1.5 Nm/13.27 lbf.in
FSC: 2.25 Nm/19.91 lbf.in
FSD/E: M6: 6 Nm/53 lbf.in
FSF:
M8: 13 Nm/115 lbf.in
Figure 4-9
Power and motor terminal layout for the PM240
Line commutating choke (Input choke)
Line commutating chokes are used to smooth voltage peaks (line disturbances) or to bridge
commutating dips. 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.
For more information on input chokes, please refer to the product catalog.
4-10
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
Installing/Mounting
4.2 Electrical Installation
Connecting example
The figure below shows the recommended power and motor connections when installing a
SINAMICS G120 inverter.
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Motor and power connections
Operation with ungrounded (IT) supplies
IT supplies are fully isolated from the protective earth system, usually by an isolating
transformer. It should be noted, however, that a protective earth is still provided.
Warning
SINAMICS G120 Power Modules with built-in filters or external filters must not be used with
IT supplies.
SINAMICS G120 Power Modules connected to IT supplies must have their internal 'Y'
capacitors disconnected (see below). If the SINAMICS G120 Power Module connected to an
IT supply is required to remain operational if an input or output phase is connected to
ground, then an output choke must be fitted to prevent tripping.
Operation of the SINAMICS G120 Power Modules without a protective earth is not permitted
under any circumstances.
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:
• A type B RCD is used.
• The trip limit of the RCD is 300 mA.
• The neutral of the supply is grounded.
• Only one SINAMICS G120 power module is supplied from each RCD.
• The output cables are less than 50 m (164 ft) screened or 100 m (328 ft) unscreened.
Avoiding Electromagnetic Interference (EMI)
The inverters are designed to operate in an industrial environment where a high level of EMI
can be expected. Most installations do not give problems. However, it is good engineering
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
4-11
Installing/Mounting
4.2 Electrical Installation
pratice to conform to the following guidelines - this will reduce the likelihood of problems
during operation.
Actions to take
• Ensure that all equipment in the cubicle is well grounded using short, thick grounding
cable connected to a common star point or busbar.
• Make sure that any control equipment (such as a PLC) connected to the inverter is
connected to the same ground or star point as the inverter using a short thick link.
• Connect the return ground from the motors controlled by the inverters directly to the
ground connection (PE) on the associated inverter.
• Flat conductors are preferred as they have lower impedance at higher frequencies.
• Terminate the ends of the cable neatly, ensuring that unscreened wires are as short as
possible.
• Separate the control cables from the power cables as much as possible, using separate
trunking, if the cables cross they should cross at 90º to each other.
• Whenever possible, use screened leads for the connections to the control circuitry.
• Ensure that the contactors in the cubicle are suppressed, either with R-C suppressors for
AC contactors or 'flywheel' diodes for DC contactors fitted to the coils. Varistor
suppressors are also effective. This is important when the contactors are controlled from
the inverter relay.
• Use screened or armored cables for the motor connections and ground the screen at
both ends using the cable clamps.
Warning
Safety regulations must not be compromised when installing inverters!
Screening methods
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.
4-12
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
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. This diagram shows both methodologies of
screening.
Note
The EMI illustration below is not to scale. The terminal cover on Frame Size D cannot be
removed. It has been removed to show the correct cable connection for the terminals.
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Figure 4-11
Example of wiring to minimize the effect of EMI
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
4-13
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.
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Motor terminal box
The following must be noted when entering the rating plate data or the ECD data:
• The outer conductor voltage/phase-to-phase voltage (voltage U12 between outer
conductors L1, L2) and the outer conductor current (phase current) I1 are always
specified on the rating plate.
• The rated motor voltage and the rated motor current must always be entered according to
the motor circuit configuration (either delta/star circuit configuration).
• If rated motor data that are available are not consistent with the motor circuit
configuration, then an appropriate conversion should be made which is then entered.
• If equivalent circuit diagram data is available, then these should be entered according to
the motor circuit configuration. If there is no consistency between the motor circuit
4-14
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
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.
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8
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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. Equivalent circuit diagram data can only be estimated from the rating plate
data; this is the reason that equivalent circuit diagram data is either determined
• using the motor data identification, or
• is entered from a motor data sheet that may be available.
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
4-15
Installing/Mounting
4.2 Electrical Installation
87 Hz characteristic
When a motor with a delta circuit configuration (e.g. VN∆, motor = 230 V) is fed from a
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:
• The motor must have the appropriate voltage strength.
• Above the rated motor frequency, the iron losses in the motor increase overproportionally. This is the reason that above this frequency, the thermal motor torque
should be reduced.
• For the quick commissioning, the rating plate data for the delta circuit configuration
should be entered or the rating plate must be appropriately converted.
• The inverter must be designed for the higher current (delta circuit configuration).
• The 87 Hz characteristic is independent of the control type and can therefore be used
both for V/f control as well as for closed-loop vector control.
• When using the 87 Hz characteristic, the mechanical motor limits must be taken into
account.
For the 87 Hz characteristic, the ratio between the voltage and frequency (V/f characteristic)
remain constant. This is the reason that the following relationships apply:
U
UN1
(400 V)
UN∆
(230 V)
f
fN∆(50 Hz) fN1(87 Hz)
Figure 4-14
V/f characteristic
Table 4-3
Example 1LA7060-4AB10
PN1 =
UN1
⋅ PNΔ
UNΔ
f N1 =
UN1
⋅ f NΔ
UNΔ
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Delta circuit
configuration
87 Hz
characteristic
Star circuit
configuration
P0304
Rated motor voltage
230 V
400 V
400 V
P0305
Rated motor current
0.73 A
0.73 A
0.42 A
P0307
Rated motor power
120 W
207 W
120 W
P0308
cos φ
0.75
0.75
0.75
P0310
Rated motor frequency
50 Hz
87 Hz
50 Hz
P0311
Rated motor speed
1350 RPM
2460 RPM
1350 RPM
P0314
Motor pole pairs
2
2
2
Contrary to the OP, the STARTER commissioning (start-up) program offers a maskorientated quick commissioning. On the other hand, the OP offers, in conjunction with the
inverter, parameter-orientated quick commissioning.
4-16
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Hardware Installation Manual, 2006-04-04, A5E00807525B AA
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.
Figure 4-15
Fitting the Control Unit to the Power Module
Caution
Before snap-on the Control Unit to the Power Module while hot swap connect 24 V supply to
the terminals.
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Hardware Installation Manual, 2006-04-04, A5E00807525B AA
4-17
Operation (hardware)
5.1
5
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:
– It is protected from the ingress of solid foreign objects ≥ 12.5 mm (0.49 inches).
– It is designed to not allow access to hazardous parts with a finger.
– It is not protected against the ingress of water.
• Keep the SINAMICS G120 Power Module free from dust and dirt.
• Keep the SINAMICS G120 Power Module away from water, solvents and chemicals.
• Keep the SINAMICS G120 Power Module within the maximum and minimum operating
temperatures.
• Ensure that the correct level of ventilation and air flow is provided.
• Ensure that good earthing/grounding practices are followed for each SINAMICS G120
Power Module and the cabinet.
Power Modules PM240
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5-1
6
Technical data
6.1
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:
Table 6-1
Distances to other equipment
Frame A
Size
mm
B
C
D
E
F
inch
mm
inch
mm
inch
mm
inch
mm
inch
mm
inch
Side
by
Side
30
1.18
40
1.57
50
1.96
0
0
0
0
0
0
Above
and
Below
100
3.93
100
3.93
125
4.92
300
11.81
300
11.81
350
13.77
Ambient operating conditions
Temperature
The normal operating temperature range of the SINAMICS G120 Power Module is as
follows:
• 0 °C … + 50 °C (32 °F … 122 °F) High Overload (HO)
• 0 °C … + 40 °C (32 °F … 104 °F) Light Overload (LO).
The ambient operating temperature is shown diagramatically in the figure below.
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
6-1
Technical data
6.1 Mechanical Data
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Figure 6-1
Power derating for temperature
Humidity range
Relative air humidity for the SINAMICS G120 Power Module is ≤ 95 % non-condensing.
In areas of high relative humidity, measures should be taken to ensure that condensation
does not form within or around the SINAMICS G120 Power Module. Anti-condensation
heaters are commonly used to prevent the formation of condensation.
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.
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Shock and vibration
Do not drop the SINAMICS G120 Power Module or expose to sudden shock. Do not install
the SINAMICS G120 Power Module in an area where it is likely to be exposed to constant
vibration.
Electromagnetic radiation
Do not install the SINAMICS G120 Power Module near sources of electromagnetic radiation.
6-2
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
Technical data
6.1 Mechanical Data
Atmospheric pollution
Do not install the SINAMICS G120 Power Module in an environment which contains
atmospheric pollutants such as dust and/or corrosive gases.
Water
Take care to site the SINAMICS G120 Power Module away from potential water hazards, for
example, do not install the SINAMICS G120 Power Module beneath pipes that are subject to
condensation. Avoid installing the SINAMICS G120 Power Module where excessive humidity
and condensation may occur.
Installation and cooling
Caution
The SINAMICS G120 Power Module MUST NOT be mounted horizontally.
When mounting SINAMICS G120 Power Modules one above the other, the specified
environmental conditions and clearance must not be exceeded (see Dimension Drawings)
Independent of this, the minimum distance above and below the SINAMICS G120 Power
Modules is 100 mm (3.9 inches).
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.
Make sure that there is an adequate airflow through the cubicle as follows:
1. Using the formula below, calculate the airflow required:
Airflow (m3/hr) = (Dissipated Watts / ΔT) x 3.1
2. If necessary, install cubicle cooling fans.
Note
Dissipation (Watts) = 3 % to 5 % of the SINAMICS G120 Power Module rating.
ΔT = Allowable temperature rise within the cubicle in °C.
3.1 = Specific heat of air at sea level.
Frame
Size
A
B
Power
Rating
0.37
0.55
0.75
1.1
1.5
2
3
4
5.5
7.5
11
Power
Losses
97
99
102
108
114
139
158
183
240
297
396
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
C
6-3
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
Frame size
Dimensions and tightening torques of SINAMICS G120 power modules
Dimensions
Height x Width x Depth (H x W x D)
(with CU)
(without CU)
mm
173 x 73 x 210
173 x 73 x 145
inch
6.81 x 2.87 x 8.27
6.81 x 2.87 x 5.71
mm
270 x 153 x 230
270 x 153 x 165
inch
10.63 x 6.02 x 9.05
10.63 x 6.02 x 6.50
mm
334 x 189 x 250
334 x 189 x 185
inch
13.1 x 7.41 x 9.84
13.1 x 7.41 x 7.28
D
Unfiltered
mm
419 x 275 x 260
419 x 275 x 204
inch
16.3 x 10.8 x 10.2
16.3 x 10.8 x 8.0
D
Filtered
mm
512 x 275 x 260
512 x 275 x 204
inch
20.1 x 10.8 x 10.2
20.1 x 10.8 x 8.0
E
Unfiltered
mm
499 x 275 x 260
499 x 275 x 204
inch
19.6 x 10.8 x 10.2
19.6 x 10.8 x 8.0
E
Filtered
mm
635 x 275 x 260
635 x 275 x 204
inch
25.0 x 10.8 x 10.2
25.0 x 10.8 x 8.0
F
Unfiltered
mm
635 x 350 x 372
635 x 350 x 316
inch
25.0 x 13.8 x 14.6
25.0 x 13.8 x 12.4
F
Filtered
mm
934 x 350 x 372
934 x 350 x 316
inch
36.8 x 13.8 x 14.6
36.8 x 13.8 x 12.4
A
B
C
6-4
Fixing method
Tightening
torques
2 x M4 bolts,
2 x M4 nuts,
2 x M4 washers
2.5 Nm
(22.1 lbf.in)
with washers
fitted.
4 x M4 bolts,
4 x M4 nuts,
4 x M4 washers
4 x M5 bolts,
4 x M5 nuts,
4 x M5 washers
4 x M6 bolts,
4 x M6 nuts,
4 x M6 washers
6 Nm
(53 lbf.in) with
washers fitted.
4 x M8 bolts,
4 x M8 nuts,
4 x M8 washers
13 Nm
(115 lbf.in) with
washers fitted.
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
Technical data
6.2 Electrical Data
6.2
Electrical Data
Power and motor connections
Warning
The SINAMICS G120 inverter must always be grounded.
Isolate the line 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.
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
3).
Caution
The control, power supply and motor cables must be laid separately. Do not feed them
through the same cable conduit or trunking.
After connecting the power and motor cables to the proper terminals, make sure that the
front covers (FSD to FSF only) have been returned to the closed position and are snapped
shut, before supplying power to the SINAMICS G120 inverter!
Notice
Ensure that the appropriate circuit-breakers/fuses with the specified current rating are
connected between the power supply and the SINAMICS G120 inverter (see Technical
data).
Use Class 1 75 °C copper wire only (for UL compliance).
For tightening torques, see Technical data.
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
6-5
Technical data
6.2 Electrical Data
Air cooling requirements
Table 6-3
Air cooling requirements
Frame size
Required cooling air flow
I/s
CFM
A
4.8
10.2
B
24.0
51.0
C
54.9
116.3
D
54.9
116.3
E
2 x 54.9
2 x 116.3
F
150.0
317.79
Relationship between pulse frequency and current reduction
Table 6-4
Power
rating at
400 V
Current reduction depending on pulse frequency
Frame
size
kW
6-6
Inverter
current
rating
Output current at pulse frequency of
at 4 kHz
6 kHz
8 kHz
10 kHz
12 kHz
14 kHz
16 kHz
A
A
A
A
A
A
A
0.37
A
1.3
1.1
0.9
0.8
0.7
0.6
0.5
0.55
A
1.7
1.4
1.2
1.0
0.9
0.8
0.7
0.75
A
2.2
1.9
1.5
1.3
1.1
1.0
0.9
1.1
A
3.1
2.6
2.2
1.9
1.6
1.4
1.2
1.5
A
4.1
3.5
2.9
2.5
2.1
1.8
1.6
2.2
B
5.9
5.0
4.1
3.5
3.0
2.7
2.4
3
B
7.7
6.5
5.4
4.6
3.9
3.5
3.1
4
B
10.2
8.7
7.1
6.1
5.1
4.6
4.1
5.5
C
13.2
11.2
9.2
7.9
6.6
5.9
5.3
7.5
C
19
16.2
13.3
11.4
9.5
8.6
7.6
11
C
26
22.1
18.2
15.6
13.0
11.7
10.4
15
D
32
27.2
22.4
19.2
16.0
14.4
12.8
18.5
D
38
32.3
26.6
22.8
19.0
17.1
15.2
22
D
45
38.3
31.5
27.0
22.5
20.3
18.0
30
E
62
52.7
43.4
37.2
31.0
27.9
24.8
37
E
75
63.8
52.5
45.0
37.5
33.8
30.0
45
F
90
76.5
63.0
54.0
45.0
40.5
36.0
55
F
110
93.5
77.0
66.0
55.0
49.5
44.0
75
F
145
123.3
101.5
87.0
72.5
65.3
58.0
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
Technical data
6.2 Electrical Data
Braking resistor data
Table 6-5
Data for braking resistors
Rated Voltage VDC_max
400 V
820 V … 840
V
IDC_max for Frame size
A
B
C
D
E
F
2.15 A
(390 Ω)
5.25 A
(160 Ω)
15 A
(56 Ω)
30.4 A
(27 Ω)
54.7 A
(15 Ω)
100.0 A
(8.2 Ω)
Power Module PM240 Specifications
Caution
High Overload (HO) and Light Overload (LO) input currents
The input current at the rated operating point - applies for the short-circuit voltage of the line
supply Vk = 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 %.
Notice
UL certified Fuses must be used
In order that the system is in compliance with UL, UL certified fuses, circiut-breaker or self
protected combination motorcontroller must be used.
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
6-7
Technical data
6.2 Electrical Data
Table 6-6
Product
6SL3224
-…
Rated Output, Input and Fuses
Power
Module
400 V
Frame
size
A
rated output
HO
LO
fuse
rated
output
current
rated
input
current
rated
output
current
rated
input
current
3NA3…/
3NE1…
kW
hp
A
A
A
A
A
Type
unfiltered
0BE137UA0
1.3
A
0.37
0.5
1.3
1.6
1.3
1.7
10
803/
-
0BE155UA0
1.7
A
0.55
0.75
1.7
2.0
1.7
2.1
10
803/
-
0BE175UA0
2.2
A
0.75
1
2.2
2.5
2.2
2.6
10
803/
-
0BE211UA0
3.1
A
1.1
1.5
3.1
3.8
3.1
3.9
10
803/
-
0BE215UA0
4.1
A
1.5
1
4.1
4.8
4.1
4.9
10
803/
-
0BE222UA0
5.9
B
2.2
3
5.9
7.6
5.9
7.6
16
805/
-
0BE230UA0
7.7
B
3
4
7.7
10.2
7.7
10.2
16
805/
-
0BE240UA0
10
B
4
5
10.2
13.4
10.2
13.4
20
807/
-
0BE255UA0
18
C
5.5
7.5
13.2
16.7
18
21.9
20
807/
-
0BE275UA0
25
C
7.5
10
19
23.7
25
31.5
32
807/
-
0BE311UA0
32
C
11
15
26
32.7
32
39.4
35
812/
-
0BE315UA0
38
D
15
20
32
40
38
46
50
820/
817-0*
0BE318UA0
45
D
18.5
25
38
46
45
53
63
822/
818-0*
0BE322UA0
60
D
22
30
45
56
60
72
80
824/
820-0*
0BE330UA0
75
E
30
40
60
73
75
88
100
830/
021-0*
0BE337UA0
90
E
37
50
75
90
90
105
125
832/
022-0*
0BE345UA0
110
F
45
60
90
108
110
129
160
836/
224-0*
0BE355UA0
145
F
55
75
110
132
145
168
200
140/
225-0*
0BE375UA0
178
F
75
100
145
169
178
204
250
144/
227-0*
6-8
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
Technical data
6.2 Electrical Data
Table 6-7
Product
6SL3224
-…
Rated Output, Input and Fuses
Power
Module
400 V
Frame
size
A
rated output
HO
LO
fuse
rated
output
current
rated
input
current
rated
output
current
rated
input
current
3NA3…/
3NE1…
kW
hp
A
A
A
A
A
Type
with filter class A
0BE222AA0
5.9
B
2.2
3
5.9
7.6
5.9
7.6
16
805/
-
0BE230AA0
7.7
B
3
4
7.7
10.2
7.7
10.2
16
805/
-
0BE240AA0
10
B
4
5
10.2
13.4
10.2
13.4
20
807/
-
0BE255AA0
18
C
5.5
7.5
13.2
16.7
18
21.9
20
807/
-
0BE275AA0
25
C
7.5
10
19
23.7
25
31.5
32
812/
-
0BE311AA0
32
C
11
15
26
32.7
32
39.4
35
814/
-
0BE315AA0
38
D
15
20
32
40
38
46
50
820/
817-0*
0BE318AA0
45
D
18.5
25
38
46
45
53
63
822/
818-0*
0BE322AA0
60
D
22
30
45
56
60
72
80
824/
820-0*
0BE330AA0
75
E
30
40
60
73
75
88
100
830/
021-0*
0BE337AA0
90
E
37
50
75
90
90
105
125
832/
022-0*
0BE345AA0
110
F
45
60
90
108
110
129
160
836/
224-0*
0BE355AA0
145
F
55
75
110
132
145
168
200
140/
225-0*
0BE375AA0
178
F
75
100
145
169
178
204
250
144/
227-0*
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
6-9
Technical data
6.2 Electrical Data
Table 6-8
Product
Input, Output Cable and Weight
Power
Module
400 V
Frame
size
6SL3224- A
…
Input cable
weight
Output cable
min.
max.
min.
max.
min.
max.
min.
max.
mm2
mm2
awg
awg
mm2
mm2
awg
awg
kg
lbs
unfiltered
0BE137UA0
1.3
A
1.0
2.5
18
14
1.0
2.5
18
14
1.2
2.6
0BE155UA0
1.7
A
1.0
2.5
18
14
1.0
2.5
18
14
1.2
2.6
0BE175UA0
2.2
A
1.0
2.5
18
14
1.0
2.5
18
14
1.2
2.6
0BE211UA0
3.1
A
1.0
2.5
18
14
1.0
2.5
18
14
1.2
2.6
0BE215UA0
4.1
A
1.0
2.5
18
14
1.0
2.5
18
14
1.2
2.6
0BE222UA0
5.9
B
1.5
6.0
16
10
1.0
6.0
18
10
4.3
9.5
0BE230UA0
7.7
B
1.5
6.0
16
10
1.0
6.0
18
10
4.3
9.5
0BE240UA0
10
B
2.5
6.0
14
10
1.0
6.0
18
10
4.3
9.5
0BE255UA0
18
C
4.0
10.0
12
8
4.0
10.0
12
8
6.5
14.3
0BE275UA0
25
C
4.0
10.0
12
8
4.0
10.0
12
8
6.5
14.3
0BE311UA0
32
C
6.0
10.0
10
8
6.0
10.0
10
8
6.5
14.3
0BE315UA0
38
D
10.0
35.0
7
2
10.0
35.0
7
2
15.9
35.1
0BE318UA0
45
D
10.0
35.0
7
2
10.0
35.0
7
2
15.9
35.1
0BE322UA0
60
D
16.0
35.0
5
2
16.0
35.0
5
2
15.9
35.1
0BE330UA0
75
E
25.0
35.0
3
2
25.0
35.0
3
2
19.8
43.7
0BE337UA0
90
E
25.0
35.0
3
2
25.0
35.0
3
2
19.8
43.7
0BE345UA0
110
F
35.0
120.0
2
4/0
35.0
120.0
2
4/0
50.7
111.8
0BE355UA0
145
F
70.0
120.0
2/0
4/0
70.0
120.0
2/0
4/0
50.7
111.8
0BE375UA0
178
F
95.0
120.0
3/0
4/0
95.0
120.0
3/0
4/0
50.7
111.8
6-10
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
Technical data
6.2 Electrical Data
Table 6-9
Product
Input, Output Cable and Weight
Power
Module
400 V
Frame
size
6SL3224- A
…
Input cable
weight
Output cable
min.
max.
min.
max.
min.
max.
min.
max.
mm2
mm2
awg
awg
mm2
mm2
awg
awg
kg
lbs
with filter class A
0BE222AA0
5.9
B
1.5
6.0
16
10
1.0
6.0
18
10
4.3
9.5
0BE230AA0
7.7
B
1.5
6.0
16
10
1.0
6.0
18
10
4.3
9.5
0BE240AA0
10
B
2.5
6.0
14
10
1.0
6.0
18
10
4.3
9.5
0BE255AA0
18
C
2.5
10.0
14
8
2.5
10.0
14
8
6.5
14.3
0BE275AA0
25
C
4.0
10.0
12
8
4.0
10.0
12
8
6.5
14.3
0BE311AA0
32
C
6.0
10.0
10
8
6.0
10.0
10
8
6.5
14.3
0BE315AA0
38
D
10.0
35.0
7
2
10.0
35.0
7
2
19.3
42.5
0BE318AA0
45
D
10.0
35.0
7
2
10.0
35.0
7
2
19.3
42.5
0BE322AA0
60
D
16.0
35.0
5
2
16.0
35.0
5
2
19.3
42.5
0BE330AA0
75
E
25.0
50.0
3
1/0
25.0
35.0
3
2
27.1
59.7
0BE337AA0
90
E
25.0
50.0
3
1/0
25.0
35.0
3
2
27.1
59.7
0BE345AA0
110
F
35.0
120.0
2
4/0
50.0
120.0
1/0
4/0
66.7
147.0
0BE355AA0
145
F
70.0
120.0
2/0
4/0
70.0
120.0
2/0
4/0
66.7
147.0
0BE375AA0
178
F
95.0
120.0
3/0
4/0
95.0
120.0
3/0
4/0
66.7
147.0
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
6-11
Technical data
6.2 Electrical Data
SINAMICS G120 Power Module
Table 6-10
Performance ratings
Feature
Specification
Line operating voltage &
power ranges
3 AC 380 V … 480 V ± 10 %
Input frequency
47 Hz … 63 Hz
Output frequency
0 Hz … 650 Hz
cos φ
0.95
Inverter efficiency
95 % … 97 %
Overload capability (HO)
1.5 x Nominal output current (150 % overload) for 57 s every 300 s
High Overload: 0.37 kW … 75 kW (0.50 hp … 100.0 hp)
Light Overload: 2.2 kW … 75 kW (3.0 hp … 100.0 hp)
2 x Nominal output current (200 % overload) for 3 s every 300 s
Overload capability (LO)
1.1 x Nominal output current (110 % overload) for 57 s every 300 s
Inrush current
Less than rated input current
Pulse frequency
4 kHz (standard); 4 kHz … 16 kHz (in 2 kHz steps)
Electromagnetic
compatibility
Optional Class A filters available according to EN 55011
Braking
DC braking, Compound braking, Dynamic braking with integrated chopper
(braking functionality depends on the type of CU and PM)
Protection level
IP20
Temperature range
0 °C … +50 °C (32 °F … 122 °F) - High Overload (HO)
1.5 x Nominal output current (150 % overload) for 3 s every 300 s
0 °C … +40 °C (32 °F … 104 °F) - Light Overload (LO)
Storage temperature
6-12
-40 °C … +70 °C (-40 °F … 158 °F)
Humidity
< 95% RH - non-condensing
Operational altitude
Up to 1000 m (3280 ft) above sea level without derating
Protection features
Undervoltage, Overvoltage, Overload, Ground faults, Short circuit, Stall
prevention, Motor blocking protection, Motor overtemperature, Power
Module overtemperature, Parameter interlock
Standards
UL, cUL, CE, C-tick
CE marked
Conformity with EC Low Voltage Directive 73/23/EEC and filtered
versions also Electromagnetic Compatibility Directive 89/336/EEC
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
Technical data
6.2 Electrical Data
Permissable Cable Length
All inverters will operate at full specification with cable lengths as follows:
• Screened
25 m (82 ft) for filtered drives
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 … 400 V ± 10 %
400 V … 480 V ± 10 %
shielded
unshielded
shielded
unshielded
A
150 m
150 m
100 m
100 m
B…C
150 m
225 m
100 m
150 m
D…F
200 m
300 m
200 m
300 m
Tightening torques for power terminals
Table 6-11
Power terminals - tightening torques
Frame size
Tightening Torques
Nm
lbf.in
A
1.1
9.7
B
1.5
13.27
C
2.25
19.91
D
6
53
E
6
53
F
13
115
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
6-13
7
Dimension drawings
7.1
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:
Table 7-1
Additional dimensions
Frame size
PM height + …
PM depth + …
mm
inch
mm
inch
--
--
65
2.56
Control Unit
all sizes
Screen termination kit w/o brake module
FSA
98
3.86
--
--
FSB
90
3.54
--
--
FSC
98
3.50
--
--
FSD
122
4.78
122
4.78
FSE
122
4.78
122
4.78
FSF
149
5.84
149
5.84
FSA
159
6.25
65
2.56
FSB
165
6.49
65
2.56
FSC
167
6.57
65
2.56
FSD
200
7.84
54
2.12
FSE
200
7.84
54
2.12
FSF
264
10.4
54
2.12
NEMA kit with top hat
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
7-1
Dimension drawings
7.1 Dimensions of the PM240
PPರ
PPರ
PPರ
PPರ
PPರ
PPರ
PPರ
PPರ
PPರ
)6$
)6%
)6&
Figure 7-1
7-2
FSA … FSC Dimensions
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
PPರ
Dimension drawings
7.1 Dimensions of the PM240
6,1$0,&6*%DXJU¸¡H'PLW)LOWHU
Figure 7-2
PPರ
PPರ
PPರ
PPರ
PPರ
PP
Frame size D (filtered) dimensions
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
7-3
PPರ
Dimension drawings
7.1 Dimensions of the PM240
6,1$0,&6*)6'RKQH)LOWHU
PPರ
Figure 7-3
7-4
PPರ
PPರ
PPರ
PPರ
PPರ
Frame size D (unfiltered) dimensions
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
PPರ
Dimension drawings
7.1 Dimensions of the PM240
6,1$0,&6*)6(PLW)LOWHU
Figure 7-4
PPರ
PPರ
PPರ
PPರ
PPರ
Frame size E (filtered) dimensions
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
7-5
PPರ
Dimension drawings
7.1 Dimensions of the PM240
6,1$0,&6*)6(RKQH)LOWHU
Figure 7-5
7-6
PPರ
PPರ
PPರ
PPರ
PPರ
PPರ
Frame size E (unfiltered) dimensions
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
PPರ
Dimension drawings
7.1 Dimensions of the PM240
6,1$0,&6*)6)PLW)LOWHU
PPರ
PPರ
PPರ
Figure 7-6
PPರ
PPರ
PPರ
Frame size F (filtered) dimensions
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
7-7
6,1$0,&6*)6)RKQH)LOWHU
PPರ
Dimension drawings
7.1 Dimensions of the PM240
PPರ
PPರ
PPರ
PPರ
PPರ
Figure 7-7
7-8
Frame size F (unfiltered) dimensions
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
Spare parts/Accessories
8.1
8
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. Frame size A contains one fan and frame size B and C
contain two fans. The Control Unit must be removed from the Power Module. Power-down
the Power Module and disconnect all cables. The Power Module must be placed face-down
on a clean and safe surface and the cooling fan removed by releasing the power connection
and the retaining screws. The new cooling fan is fitted in reverse order.
To replace the cooling fan on the SINAMIC G120 Power Modules for FSA, FSB and FSC,
the following procedure should be performed. Please refer the Figure below.
1. Power-down the inverter.
2. Remove the Control Unit from the inverter.
3. Disconnect all the cables from the Power Module.
4. Release the fan cable connector(s) ①.
5. Using a posi-drive screwdriver, remove the fan retaining screws ②.
6. Slide the cooling fan out from the inverter.
7. Fit the new cooling fan into the fan housing area.
8. Secure the replacement cooling fan in place by tighten the retaining screws ②.
9. Re-attach the fan cable connector(s) ①.
10.Mount the Power Module.
11.Reconnect all the necessary cables to the Power Module.
12.Reattach the Control Unit.
13.Check that the installation is correct and safely installed.
14.Apply power the system.
15.Check that the cooling fan(s) are running correctly.
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
8-1
Spare parts/Accessories
8.1 Replacing a Cooling Fan
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8-2
Replacing the cooling fan
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
Spare parts/Accessories
8.2 Power Module accessories
8.2
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.
The DRMK for FSA allows for the mounting of either the inverter as a stand-alone or with the
inverter and the footprint filter. The FSB inverters, due to their physical size and weight can
only be mounted as stand-alone inverters.
The EM brake or safe brake module can only be mounted on the FSA or FSB DIN rail when
used in conjunction with the relevant screen termination kit, see table below.
The required DIN rail pitch for each frame size are given in the table below.
Table 8-1
DIN rail pitch
Frame size
DIN rail pitch (mm)
FSA
115 (± 1)
FSB
115 (± 1)
Ordering information is given in the following table:
Table 8-2
DIN rail mounting kit ordering information
Description
Order No.
G120/S120 FSA DIN Rail Kit
6SL3262-1BA00-0BA0
G120/S120 FSB DIN Rail Kit
6SL3262-1BB00-0BA0
NEMA 1 kit
The NEMA 1 kit has been designed to provide some protection against limited amounts of
falling dirt in an indoor environment. The level of protection does not protect against falling
liquids.
The NEMA 1 kit only provides protection for the inverter itself and does not protect any of the
footprint options or the DIN rail kit.
The kit provides protection for both the power module and the control unit including easy
access to the MMC on the control unit.
The NEMA 1 kit consists of the following components:
• Top cover (to protect the top of the inverter).
• Metal glanding box (to allow the correct termination of control cables).
• Gland box cover (to ensure that the control cables can not be touched accidentally).
Ordering information is given in the following table:
Power Modules PM240
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8-3
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
6SL3262-1CF00-0DA0
Screen termination kit
The screen termination kit has been designed to allow the termination of control, mains and
power cables to ensure the correct electrical grounding to the inverter.
For FSA the screen termination kit provides for the termination of 3 screened cables.
For FSB and larger the screen termination kits provides for the termination of at least 4
screened cables.
Ordering information is given in the following table:
Table 8-4
Screen termination kit ordering information
Description
Order No.
G120/S120 FSA Screen Termination Kit
6SL3262-1AA00-0BA0
G120/S120 FSB Screen Termination Kit
6SL3262-1AB00-0DA0
G120/S120 FSC Screen Termination Kit
6SL3262-1AC00-0DA0
G120/S120 FSD Screen Termination Kit
6SL3262-1AD00-0DA0
G120/S120 FSE Screen Termination Kit
6SL3262-1AD00-0DA1
G120/S120 FSF Screen Termination Kit
6SL3262-1AF00-0DA0
Brake modules
The brake modules are designed to provide the interface between the Control Module/Power
Module and the brake solenoid of a motor. There are two versions:
• Brake module – this provides the basic braking control function.
• Safe brake module – this provides for the braking control function within a safety
integrated system. To adhere to the requirements of a safety integrated system, the safe
brake module has been designed to allow a variable voltage to be given to the safe brake
module to allow the system to determine if the brake module is functioning correctly
without actually activating the braking function.
The brake modules can be panel mounted, wall mounted or mounted on the screen
termination plates and gland kits.
Ordering information is given in the following table:
8-4
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
Spare parts/Accessories
8.2 Power Module accessories
Table 8-5
Brake module ordering information
Description
Order No.
Brake Module
6SL3252-0BB00-0AA0
Safe Brake Module
6SL3252-0BB01-0AA0
Chokes and filters
Class B, EMC filters
These external filters are fitted on the mains supply into the inverter and are used to
suppress Radio Frequency Interference (RFI). To meet the requirements of Class B RFI
emissions shielded cable should be used and must not exceed a maximum length of 25 m
[82 ft] to 50 m [164 ft] – depending on the specific type of filter.
LC filters and sinusoidal filters
The LC filter and sinusoidal filter is designed to limit the rate of rise of voltage and the
capacitive charge or discharge currents which usually occur with inverter operation. This
means that much longer shielded motor cables are possible when using LC filters and
sinusoidal filters and the service life of the motor achieves values similar to those with direct
mains operation.
Line commutating choke (Input choke)
Line commutating chokes are used to smooth voltage peaks (line disturbances) or to bridge
commutating dips. 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.
For more information on input chokes, please refer to the product catalog.
Output choke
Output chokes can be used to reduce the capacitive compensation currents and dV/dt in the
case of motor cables greater than 50 m [164 ft] (shielded) or less than 100 m [328 ft]
unshielded.
Ordering information is given in the following table:
Table 8-6
Choke and filter ordering information
Description
Order No.
G120/S120 FSB Class B Supp Filter
6SL3203-0BE21-6SA0
G120/S120 FSC Class B Supp Filter
6SL3203-0BD23-8SA0
G120/S120 FSB Input Choke (9.0 A)
6SL3203-0CD21-0AA0
G120/S120 FSB Input Choke (12.1 A)
6SL3203-0CD21-4AA0
G120/S120 FSC Input Choke (20.5 A)
6SL3203-0CD22-2AA0
G120/S120 FSC Input Choke (29.3 A)
6SL3203-0CD23-5AA0
G120/S120 FSD 400 V 18,5 kW Input Choke
6SL3203-0CD25-3AA0
G120/S120 FSD 400 V 22 kW Input Choke
6SL3203-0CJ24-5AA0
G120/S120 FSE 400 V Input Choke
6SL3203-0CJ28-6AA0
G120/S120 FSB Output Choke
6SL3202-0AE21-0CA0
G120/S120 FSC Output Choke
6SL3202-0AJ23-2CA0
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
8-5
Spare parts/Accessories
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. The inverter transfers the excess energy to the externally
mounted braking resistor. The option is only available for the Frame Size B inverter.
Ordering information is given in the following table:
Table 8-7
8-6
Braking resistor ordering information
Description
Order No.
G120/S120 FSB Braking Resistor
6SL3201-0BE12-0AA0
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
Spare parts/Accessories
8.3 Brake Control Relays
8.3
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".
Connections of Relay Brake Module and Safe Brake Module:
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Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
8-7
Spare parts/Accessories
8.3 Brake Control Relays
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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. Necessary is an external controlled power supply for 2.5 A and an output voltage
which can be adjusted at a voltage of 26 V, e.g. SITOP modular. The higher voltage is
required to compensate the voltage drop across the cables to the coil of the brake.
Note
On fail-safe reasons it is not allowed to take the 24 V supply of the Control Unit.
The power supply for the Safe Brake Module must be a separate additional power supply.
During power ON for the drive it is necessary to supply the Safe Brake Module first, so that
the Control Unit is able to check its function, otherwise the fault F1601 will occur.
The Safe Brake Module is designed to reaction to a stepped voltage input, which allows the
braking mechanism to be tested. The Relay Brake Module does not have this functionality.
8-8
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
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. It controls a brake
relay, connected to the power module. This brake relay controls an electro-mechanical
brake, which is always closed when powered down.
P1215 = 0
(motor brake not active - factory setting), that means, if a brake is available, it will be closed
to prevent the motor against unintended moves, e.g. after a parameter download.
P1215 = 1
(motor brake active) the brake will be controlled via terminals A and B on the power module.
Triggering the Brake Control with Fail-safe Contol Units
Prerequisite: P1215 = 1
Warning
The brake can be triggered via both, a Relay Brake Module and a Safe Brake Module.
Triggering via a Relay Brake Module is not fail-safe!
For a fail-safe triggering of a Safe Brake Module the following parameters must be set:
P9602 = P9802 = 1 (factory setting is 0). If P9602 ≠ P9802 a fault will be generated.
In case of P9602 = P9802 = 1 a test signal regarding the signal to the Safe Brake Control is
generated and monitored.
This test signal does not interfere with the normal function of the mechanical brake. If the
mechanical brake is fitted and the test fails, a fault condition will be indicated by the inverter.
If the Safe Brake Control is deactivated by setting P9602 = P9802 = 0 the Safe Brake
Module will still work as intendet but will not be monitored in a safe way.
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
8-9
A
Appendix
A.1
Electromagnetic Compatibility
Electromagnetic compatibility
All manufacturers/assemblers of electrical apparatus which “performs a complete intrinsic
function and is placed on the market as a single unit intended for the end user” must comply
with the EMC directive EC/89/336.
There are three routes for the manufacturer/assembler to demonstrate compliance:
Self certification
This is a manufacturer's declaration that the European standards applicable to the electrical
environment for which the apparatus is intended have been met. Only standards that have
been officially published in the Official Journal of the European Community can be cited in
the manufacturer's declaration.
Technical construction file
A technical construction file can be prepared for the apparatus describing its EMC
characteristics. This file must be approved by a ‘Competent Body’ appointed by the
appropriate 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
A-1
Appendix
A.2 Definition of the EMC Environment and Categories
A.2
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.
Note
For example: houses, apartments, commercial premises or offices in a residential building.
Second Environment
An environment that includes industrial premises and establishments that are not connected
directly to a public low-voltage power supply network.
Note
For example: industrial and technical areas of buildings fed from a dedicated transformer.
• Category C1
Power Drive System (PDS) of rated voltage less than 1000 V intended for use in the First
(Domestic) Environment.
• Category C2
Power Drive System (PDS) of rated voltage less than 1000 V, which is neither a plug in
device nor a movable device, and when used in the First (Domestic) Environment, is only
intended to be installed and commissioned by a professional.
Note
A professional is a person or an organization having necessary skills in installing and/or
commissioning a Power Drive System (PDS), including their EMC aspects.
A-2
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
Appendix
A.2 Definition of the EMC Environment and Categories
• Category C3
Power Drive System (PDS) of rated voltage less than 1000 V intended for use in the
Second (Industrial) Environment and not intended for use within the First (Domestic)
Environment.
Table A-1
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.
Class A: 25 m screened cable type CY
The FSA power variant (400 V, 370 W … 1.5 kW) requires either a
footprint filter option (6SE6400-2FA00-6AD0) or additional power-line
filtering at the "system level".
When used in the First (Domestic) Environment this product may cause
radio interference in which case mitigation measures may be required.
Category C3 - Second Environment
Unfiltered Variants
All units are available as unfiltered variants.
6SL3224-0BE**-*U*0
Drives FSA … FSF (400 V, 370 W … 90 kW)
The use of unfiltered drives within an industrial installation is only possible
if it forms part of a system which includes additional power-line filtering at
the "system level" or, alternatively, the use of filtered variants.
Note
All drives should be installed and commissioned in accordance with the manufacturer’s
guidelines and in accordance with good EMC practices.
For further information refer to SIEMENS application note “EMC Design Guidelines”.
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
A-3
Appendix
A.3 EMC Overall Performance
A.3
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
EN 55011
Class A
Radiated Emissions
EN 55011
Class A
Note
To achieve this performance the default switching frequency should not be exceeded.
In order to achieve conducted emissions to EN 55011 Class B there is a range of PM240
external filter options available.
Achieving radiated emissions to EN 55011 Class B is largely dependent on the drive being
correctly installed inside a metallic enclosure. The limits will not be met if the drive is not
enclosed or installed in accordance with good EMC practices.
Harmonic Currents
The harmonic current emissions from the SINAMICS G120 drives is as follows:
Table A-3
Harmonic Currents
Rating
FSA … FSF
(400 V, 370 W … 90 kW)
Typical Harmonic Current (% of rated input current)
5th
7th
11th
13th
17th
19th
23rd
25th
73
52
25
23
22
15
12
10
Note
Units installed within the category C2 (domestic) environment require supply authority
acceptance for connection to the public low-voltage power supply network. Please contact
your local supply network provider.
Units installed within the category C3 (industrial) environment do not require connection
approval.
A-4
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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
4 kV Contact discharge
A
Radio-frequency
Electromagnetic Field
EN 61000-4-3
8 kV Air discharge
80 MHz … 1000 MHz
A
10 V/m
Amplitude modulated
80 % AM at 1 kHz
Fast Transient Bursts
EN 61000-4-4
2 kV @ 5 kHz
A
Surge Voltage
EN 61000-4-5
1 kV differential (L-L)
A
1.2/50 μs
Conducted
2 kV common (L-E)
EN 61000-4-6
0.15 MHz … 80 MHz
A
10 V/rms
Radio-frequency Common Mode
Mains Interruptions & Voltage
Dips
80 % AM at 1 kHz
EN 61000-4-11
100 % dip for 3 ms
A
30 % dip for 10 ms
B
60 % dip for 100 ms
C
95 % dip for 5000 ms
D
10 % THD
A
3 % Negative Phase
Sequence
A
A
A
Voltage Distortion
EN 61000-2-4
Voltage Unbalance
EN 61000-2-4
Frequency Variation
EN 61000-2-4
Class 3
Nominal 50 Hz or 60 Hz
(± 4 %)
Commutation Notches
EN 60146-1-1
Depth = 40 %
Class B
Area = 250 % x degrees
Class 3
Class 3
Note
The immunity requirements apply equally to both filtered and unfiltered units.
Power Modules PM240
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A-5
Appendix
A.4 Standards
A.4
Standards
European Low Voltage Directive
The SINAMICS G120 product range complies with the requirements of the Low Voltage Directive
73/23/EEC as amended by Directive 98/68/EEC. The units are certified for complaince with the following
standards:
EN 61800-5-1 — Semiconductor inverters –General requirements and line commutated inverters
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. A Declaration of Incorporation is available on
request.
European EMC Directive
When installed according to the recommendations described in this manual, the SINAMICS G120 fulfils
all requirements of the EMC Directive as defined by the EMC Product Standard for Power Drive Systems
EN 61800-3
Underwriters Laboratories
UL and CUL LISTED POWER CONVERSION EQUIPMENT for use in a pollution degree 2 environment.
Note: UL certification is presently in progress.
ISO 9001
Siemens plc operates a quality management system, which complies with the requirements of ISO 9001.
A-6
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
B
List of abbreviations
Abbreviations used with the SINAMICS G120 Products
Table B-1
Abbreviations used with the SINAMICS G120 Products
Abbreviations
State
A
AC
Alternating Current
A/D
Analog digital converter
ADR
Address
AFM
Additional frequency modification
AG
Automation Unit
AI
Analog input
AK
Request Identifier
AO
Analog output
AOP
Advanced operation panel
ASIC
Application-specific integrated circuit
ASP
Analog setpoint
ASVM
Asymmetric space vector modulation
B
BCC
Block check character
BCD
Binary-coded decimal code
BI
Binector input
BIA
Berufsgenossenschaftliches Institut für Arbeitssicherheit
BICO
Binector/connector
BO
Binector output
C
C
Commissioning
CB
Communication board
CCW
Counter-clockwise
CDS
Command data set
CI
Connector input
CM
Configuration management
CMD
Command
CO
Connector output
CO/BO
Connector output/Binector output
COM
Common (terminal is connected to NO or NC)
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B-1
List of abbreviations
A.4 Standards
Abbreviations
State
CT
Commissioning, ready to run
CU
Control Unit
CUT
Commissioning, run, ready to run
CW
Clockwise
D
D/A
Digital analog converter
DC
Direct current
DDS
Drive data set
DI
Digital input
DIP
DIP switch
DO
Digital output
DP
Distributed I/Os
DP-V1
Acyclic data transfer (extended PROFIBUS function)
DS
Drive state
E
ECD
Equivalent circuit diagram
EEC
European Economic Community
EEPROM
Electrical erasable programmable read-only memory
ELCB
Earth leakage circuit breaker
EMC
Electromagnetic compatibility
EMF
Electromagnetic force
ES
Engineering System
FAQ
Frequently asked question
F
FB
Function block
FFB
Freely Assignable Function block
FCC
Flux current control
FCL
Fast current limiting
FF
Fixed frequency
FFB
Free function block
FOC
Field orientated control
FREQ
Frequency
FSA
Frame size A
FSB
Frame size B
FSC
Frame size C
FSD
Frame size D
FSE
Frame size E
FSF
Frame size F
G
B-2
GSD
Device Data File (Geräte Stamm Datei)
GSG
Getting Started Guide
GUI ID
Global unique identifier
Power Modules PM240
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List of abbreviations
A.4 Standards
Abbreviations
State
H
HIW
Main actual value
HMI
Human machine interface
HO
High Overload (Constant Torque)
HSW
Main setpoint
HTL
High-voltage transistor logic
I
I/O
In-/output
IBN
Commissioning
IGBT
Insulated gate bipolar transistor
IND
Sub-index
J
JOG
JOG
K
KIB
Kinetic buffering
L
LCD
Liquid crystal display
LED
Light emitting diode
LGE
Length
LO
Light Overload (Variable Torque)
LWL
Fiber Optic conductor
LSTO
Latched Safe Torque Off
M
MHB
Motor holding brake
MLP
Multi-Language Pack
MOP
Motor operated potentiometer
N
NC
Normally closed
NEMA
National Electrical Manufacturers Association
NO
Normally open
O
OLM
Optical Link Module
OLP
Optical Link Plug
OM
Object Manager
OP
Operator Panel
OPI
Operating Instructions
PA
PID
Proportional, integral, derivative controller
PKE
Parameter ID
PKW
Parameter ID value area (Parameterkennung Wert)
PLC
Programmable logic control
PM
Power module
Power Modules PM240
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B-3
List of abbreviations
A.4 Standards
Abbreviations
State
PM-IF
Power module interface
PNU
Parameter Number
PNO
PROFIBUS Nutzerorganisation
PPO
Parameter process data object
PTC
Positive temperature coefficient
PWE
Parameter value
PWM
Pulse-width modulation
Pxxxx
Write parameter
PZD
Process data area (Prozeßdaten)
Q
QC
Quick commissioning
R
RAM
Random-access memory
RCCB
Residual current circuit breaker
RCD
Residual current device
RFG
Ramp-function generator
RFI
Radio frequency interference
ROM
Read-only memory
RPM
Revolutions per minute
rxxxx
read-only parameters of analogue signals
S
SBC
Safe Break Control
SLVC
Sensorless vector control
SLS
Safe-Limited Speed
SOL
Serial option link
SS1
Safe Stop 1
STO
Safe Torque Off
STW
Control word
STX
Start of text
SVM
Space vector modulation
T
TTL
Transistor-transistor logic
U
USS
Universal serial interface
V
V/f
Voltage/frequency
VC
Vector control
VT
Variable torque
W
WEA
Automatic restart
Z
ZSW
B-4
Status word
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
List of abbreviations
A.4 Standards
Abbreviations
State
ZUSW
Additional setpoint
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
B-5
Index
8
87 Hz characteristic, 4-16
A
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
EMC Standards, A-1
European EMC Directive, A-6
European Low Voltage Directive, A-6
European Machinery Directive, A-6
F
Fitting the Control Unit to the Power Module, 4-17
G
General rules for the environmental protection, 4-4, 5-1
B
H
Brake modules, 8-4
Braking resistor, 8-6
Braking resistors, 6-7
High Overload (HO) input currents, 6-7
Humidity range, 6-2
C
Chokes and filters, 8-5
Classification of EMC performance, A-2
Control Units
Overview, 3-1
Current reduction, 6-6
D
Dimension Drawings, 7-1
Dimensions and tightening torques of power
modules, 4-2, 6-4
DIN rail mounting kit, 8-3
Distances to other equipment, 4-1, 6-1
Drill patterns for power modules, 4-2
E
Electrical installation, 2-4, 4-5
Electromagnetic compatibility, A-1
Electromagnetic Interference (EMI), 4-11
Electromagnetic radiation, 6-2
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
I
Input Currents
High Overload, 6-7
Light Overload, 6-7
Installation and cooling, 6-3
ISO 9001, A-6
L
Light Overload (HO) input currents, 6-7
Line commutating choke (input chokes), 4-10
M
Mechanical installation, 2-3, 4-1
Motor Circuit, 4-14
N
NEMA 1 kit, 8-3
Index-1
Index
O
T
Operation with Residual Current Devices (RCD), 4-11
Operation with ungrounded supplies, 4-11
Options for SINAMICS G120, 3-4
Overview
Control Units, 3-1
Power Modules, 3-1
Technical construction file, A-1
Temperature, 6-1
Tightening torques for power terminals, 6-13
P
U
UL certified Fuses, 6-7
Underwriters Laboratories, A-6
Power and motor terminal layout, 4-10
Power Modules
W
Dimension Drawings, 7-1
Water, 6-3
Dimensions and tightening torques of, 4-2, 6-4
Drill patterns for, 4-2
Fitting the Control Unit to the, 4-17
General rules for the environmental protection of, 44, 5-1
Overview, 3-1, 3-2
Performance ratings, 6-12
Power range, 3-2
Specifications, 6-7
Power range of power modules, 3-2
Pulse frequency, 6-6
R
Reforming the capacitors, 4-8
Risk of electric shock, 2-2
S
Safety
Risk of Shock, 2-2
Safety notes
Commissioning, 2-3
Dismantling and disposal, 2-6
Electrical installation, 2-4, 4-5
General Warnings, Cautions and Notices, 2-1
Mechanical installation, 2-3, 4-1
Operation, 2-5
Power and motor connections, 6-5
Repair, 2-5
Safety Instructions, 2-1
Transport and storage, 2-2
Screen termination kit, 8-4
Screening methods, 4-12
Screening without a Screen Termination Kit, 4-13
Self certification, A-1
Shock and vibration, 6-2
Standards, A-6
Index-2
Power Modules PM240
Hardware Installation Manual, 2006-04-04, A5E00807525B AA
Siemens AG
Automation and Drives
Standard Drives
Postfach 32 69
91050 Erlangen
Deutschland
www.siemens.de/sinamics-g120