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.
Table of contents 1 Introduction............................................................................................................................................. 1-1 1.1 Documents for the SINAMICS G120 ......................................................................................... 1-1 2 Safety notes............................................................................................................................................ 2-1 3 Description..........................
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.............................................................
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.
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.
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.
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.
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.
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.
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.
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.
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).
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.
Description 3.3 Block diagram PM240 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.
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.
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.
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.
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).
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.
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.
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.
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.
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.
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.
Installing/Mounting 4.2 Electrical Installation Connecting example The figure below shows the recommended power and motor connections when installing a SINAMICS G120 inverter. / / / 6FKPHO] VLFKHUXQJ 'UHKVWURP 6FK¾W] 2SWLRQDOH 1HW]GURVVHO 2SWLRQDOHU )LOWHU 6,1$0,&6 * / 0RWRU 8 / 9 / : 3( 3( Figure 4-10 3( Motor and power connections Operation with ungrounded (IT) supplies IT supplies are fully isolated from the protective earth system, usually by an isolating transformer.
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.
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.
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.
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.
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.
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.
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).
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.
Technical data 6.1 Mechanical Data =XO¦VVLJHU $XVJDQJVVWURP > @ /HLFKWH EHUODVW /2 +RKH EHUODVW +2 >r&@ 8PJHEXQJVWHPSHUDWXU 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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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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.
Spare parts/Accessories 8.
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.
Spare parts/Accessories 8.2 Power Module accessories Table 8-3 NEMA 1 kit ordering information Description Order No.
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).
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.
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".
Spare parts/Accessories 8.3 Brake Control Relays )UHLH =XOHLWXQJ ]X 3RZHU 0RGXOH 9HUELQGXQJ ]X %UHPVVSXOH LP 0RWRU Figure 8-4 9HUELQGXQJ ]X H[WHUQHU 9 9HUVRUJXQJ Safe Brake Module )UHLH =XOHLWXQJ ]X Sicherheitsbremseinheit 3RZHU 0RGXOH ]X 3RZHU 0RGXOH PE CTRL H[W '& 9 Figure 8-5 + 6FKDOWXQJ + (BR+) COIL - (BR-) M 3~ M 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.
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.
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.
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.
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.
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.
Appendix A.
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.
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 ch
List of abbreviations A.
List of abbreviations A.
List of abbreviations A.
List of abbreviations A.
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) i
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 th
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