Siemens Sinamics G120,PM240 Hardware Installation Manual

Power Modules PM240

___________________

SINAMICS

SINAMICS G120 Power Modules PM240

Hardware Installation Manual

07/2016

A5E36985441C AA

Changes in this manual

Fundamental safety instructions

Introduction

Installing/mounting

Connecting-up

Service and maintenance

Technical data

Spare parts and accessories

Appendix

Siemens AG Division Digital Factory Postfach 48 48 90026 NÜRNBERG GERMANY

A5E36985441C AA

Ⓟ

Legal information

Warning notice system

DANGER

indicates that death or severe personal injury will result if proper precautions are not taken.

WARNING

indicates that death or severe personal injury may result if proper precautions are not taken.

CAUTION

indicates that minor personal injury can result if proper precautions are not taken.

NOTICE

indicates that property damage can result if proper precautions are not taken.

Qualified Personnel

personnel qualified

Proper use of Siemens products

WARNING

Siemens products may only be used for the applications described in the catalog and in the relevant technical

maintenance are required to ensure that the products operate safely and without any problems. The permissible ambient conditions must be complied with. The information in the relevant documentation must be observed.

Trademarks

Disclaimer of Liability

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.

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.

The product/system described in this documentation may be operated only by task in accordance with the relevant documentation, in particular its warning notices and safety instructions. Qualified personnel are those who, based on their training and experience, are capable of identifying risks and avoiding potential hazards when working with these products/systems.

Note the following:

documentation. If products and components from other manufacturers are used, these must be recommended or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and

All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.

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.

for the specific

06/2016 Subject to change

1 Changes in this manual ........................................................................................................................... 9

2 Fundamental safety instructions ............................................................................................................ 11

3 Introduction ........................................................................................................................................... 19

4 Installing/mounting ................................................................................................................................ 21

5 Connecting-up ...................................................................................................................................... 35

2.1 General safety instructions ..................................................................................................... 11

2.2 Safety instructions for electromagnetic fields (EMF) .............................................................. 15

2.3 Handling electrostatic sensitive devices (ESD) ...................................................................... 15

2.4 Industrial security .................................................................................................................... 16

2.5 Residual risks of power drive systems .................................................................................... 17

3.1 PM240 Power Modules ........................................................................................................... 19

3.2 Component specification according to UL .............................................................................. 20

4.1 Installation conditions.............................................................................................................. 21

4.2 EMC-compliant installation of a plant or machine .................................................................. 22

4.2.1 Control cabinet ........................................................................................................................ 22

4.2.2 Cables ..................................................................................................................................... 25

4.2.3 Electromechanical components .............................................................................................. 27

4.3 Power losses and air cooling requirements ............................................................................ 28

4.4 Mounting the Power Modules ................................................................................................. 30

4.4.1 Dimension drawings and drilling dimensions, FSA ... FSF ..................................................... 31

4.4.2 Dimensioned drawings and drilling dimensions, FSGX .......................................................... 33

4.5 Additional components............................................................................................................ 34

5.1 Permissible line supplies ........................................................................................................ 38

5.1.1 TN line system ........................................................................................................................ 38

5.1.2 TT line system ......................................................................................................................... 39

5.1.3 IT system ................................................................................................................................ 39

5.1.4 Protective conductor ............................................................................................................... 40

5.2 Connecting the line and motor cable at the inverter ............................................................... 42

5.2.1 Connection overview............................................................................................................... 42

5.2.2 Connecting inverters in compliance with EMC regulations..................................................... 43

5.2.3 Length of motor cable ............................................................................................................. 43

5.2.4 Inverter terminals .................................................................................................................... 45

5.2.5 Establishing connections ........................................................................................................ 46

5.2.5.1 Connections FSA ... FSC ........................................................................................................ 46

5.2.5.2 Connections FSD … FSF ....................................................................................................... 46

5.2.5.3 Connections FSGX ................................................................................................................. 47

5.3 Connecting the motor to the inverter in a star or delta connection ......................................... 49

Power Modules PM240 Hardware Installation Manual, 07/2016, A5E36985441C AA

Table of contents

6 Service and maintenance ...................................................................................................................... 51

7 Technical data ...................................................................................................................................... 61

8 Spare parts and accessories ................................................................................................................. 81

6.1 Maintenance ........................................................................................................................... 52

6.2 Commissioning after a long storage time .............................................................................. 53

6.3 Replace the fan ...................................................................................................................... 54

6.4 Replacing the FSGX power block .......................................................................................... 59

7.1 Ambient conditions ................................................................................................................. 61

7.2 Overload capability of the inverter ......................................................................................... 63

7.3 Cable cross-sections and tightening torques ......................................................................... 64

7.4 General data .......................................................................................................................... 65

7.5 Specific technical data ........................................................................................................... 65

7.5.1 Current derating depending on the pulse frequency.............................................................. 70

7.6 Restrictions for special ambient conditions ............................................................................ 71

7.7 Electromagnetic compatibility of variable-speed drives ......................................................... 73

7.7.1 Inverter applications ............................................................................................................... 75

7.7.1.1 Operation in the second environment .................................................................................... 75

7.7.1.2 Operation in the first environment .......................................................................................... 77

7.7.2 Radio interference suppression filters according to CISPR 11/EN 55011 Class B ............... 78

7.7.3 Harmonic currents .................................................................................................................. 78

7.7.4 EMC limit values in South Korea ........................................................................................... 79

8.1 Product maintenance ............................................................................................................. 81

8.2 Spare parts ............................................................................................................................. 81

8.3 Optional accessories .............................................................................................................. 82

8.3.1 Base components for frame sizes FSA, FSB and FSC ......................................................... 82

8.3.2 Line reactor ............................................................................................................................ 84

8.3.3 Line filter ................................................................................................................................. 88

8.3.4 Output reactor ........................................................................................................................ 90

8.3.5 Sine-wave filter....................................................................................................................... 94

8.3.6 Braking Module - only FSGX ................................................................................................. 98

8.3.6.1 Braking Module - settings and connections ........................................................................... 99

8.3.7 Braking resistor .................................................................................................................... 100

8.3.7.1 Connect the temperature contact of the braking resistor ..................................................... 104

8.3.8 Connecting a motor holding brake to a Safe Brake Relay ................................................... 104

8.3.8.1 Mounting and connecting the brake relay ............................................................................ 105

8.3.8.2 Mounting and connecting the Safe Brake Relay .................................................................. 106

8.3.8.3 Technical data of the brake relay? ....................................................................................... 106

8.3.8.4 Mounting and connecting the brake relay ............................................................................ 107

8.3.9 For standard rail mounting ................................................................................................... 108

8.3.10 Shield connection kit ............................................................................................................ 108

Power Modules PM240

6 Hardware Installation Manual, 07/2016, A5E36985441C AA

Table of contents

A Appendix............................................................................................................................................. 109

Index................................................................................................................................................... 117

A.1 Manuals and technical support ............................................................................................. 109

A.1.1 Overview of the manuals ...................................................................................................... 109

A.1.2 Configuring support ............................................................................................................... 111

A.1.3 Product Support .................................................................................................................... 112

A.2 Disposal ................................................................................................................................ 113

A.3 Directives and standards ...................................................................................................... 114

A.4 Abbreviations ........................................................................................................................ 116

Power Modules PM240 Hardware Installation Manual, 07/2016, A5E36985441C AA

Table of contents

Power Modules PM240

8 Hardware Installation Manual, 07/2016, A5E36985441C AA

Changes with respect to the manual, Edition 07/2009

All chapters in the manual have been completely revised.

Power Modules PM240 Hardware Installation Manual, 07/2016, A5E36985441C AA

Changes in this manual

Power Modules PM240

10 Hardware Installation Manual, 07/2016, A5E36985441C AA

2.1

General safety instructions

DANGER

Danger to life due to live parts and other energy sources

WARNING

Danger to life through a hazardous voltage when connecting an unsuitable power supply

Death or serious injury can result when live parts are touched.

• Only work on electrical devices when you are qualified for this job.

• Always observe the country-specific safety rules.

Generally, six steps apply when establishing safety:

1. Prepare for shutdown and notify all those who will be affected by the procedure.

2. Disconnect the machine from the supply. – Switch off the machine. – Wait until the discharge time specified on the warning labels has elapsed. – Check that it really is in a no-voltage condition, from phase conductor to phase

conductor and phase conductor to protective conductor. – Check whether the existing auxiliary supply circuits are de-energized. – Ensure that the motors cannot move.

3. Identify all other dangerous energy sources, e.g. compressed air, hydraulic systems, or water.

4. Isolate or neutralize all hazardous energy sources by closing switches, grounding or short-circuiting or closing valves, for example.

5. Secure the energy sources against switching on again.

6. Ensure that the correct machine is completely interlocked.

After you have completed the work, restore the operational readiness in the inverse sequence.

Touching live components can result in death or severe injury.

• Only use power supplies that provide SELV (Safety Extra Low Voltage) or PELV- (Protective Extra Low Voltage) output voltages for all connections and terminals of the electronics modules.

Power Modules PM240 Hardware Installation Manual, 07/2016, A5E36985441C AA

Fundamental safety instructions

WARNING

Danger to life when live parts are touched on damaged devices

WARNING

Danger to life through electric shock due to unconnected cable shields

WARNING

Danger to life due to electric shock when not grounded

WARNING

Danger to life due to electric shock when opening plug connections in operation

NOTICE

Material damage due to loose power connections

2.1 General safety instructions

Improper handling of devices can cause damage.

For damaged devices, hazardous voltages can be present at the enclosure or at exposed components; if touched, this can result in death or severe injury.

• Ensure compliance with the limit values specified in the technical data during transport, storage and operation.

• Do not use any damaged devices.

Hazardous touch voltages can occur through capacitive cross-coupling due to unconnected cable shields.

• As a minimum, connect cable shields and the conductors of power cables that are not used (e.g. brake cores) at one end at the grounded housing potential.

For missing or incorrectly implemented protective conductor connection for devices with protection class I, high voltages can be present at open, exposed parts, which when touched, can result in death or severe injury.

• Ground the device in compliance with the applicable regulations.

When opening plug connections in operation, arcs can result in severe injury or death.

• Only open plug connections when the equipment is in a no-voltage state, unless it has been explicitly stated that they can be opened in operation.

Insufficient tightening torques or vibrations can result in loose electrical connections. This can result in damage due to fire, device defects or malfunctions.

• Tighten all power connections with the specified tightening torques, e.g. line supply connection, motor connection, DC link connections.

• Check all power connections at regular intervals. This applies in particular after transport.

Power Modules PM240

12 Hardware Installation Manual, 07/2016, A5E36985441C AA

Fundamental safety instructions

WARNING

Danger to life due to fire spreading if housing is inadequate

WARNING

Danger to life through unexpected movement of machines when using mobile wireless devices or mobile phones

WARNING

Danger to life due to the motor catching fire in the event of insulation overload

WARNING

Danger to life due to fire if overheating occurs because of insufficient ventilation clearances

WARNING

Danger of an accident occurring due to missing or illegible warning labels

2.1 General safety instructions

Fire and smoke development can cause severe personal injury or material damage.

• Install devices without a protective housing in a metal control cabinet (or protect the

device by another equivalent measure) in such a way that contact with fire is prevented.

• Ensure that smoke can only escape via controlled and monitored paths.

Using mobile wireless devices or mobile phones with a transmit power > 1 W closer than approx. 2 m to the components may cause the devices to malfunction, influence the functional safety of machines therefore putting people at risk or causing material damage.

• Switch the wireless devices or mobile phones off in the immediate vicinity of the

components.

There is higher stress on the motor insulation through a ground fault in an IT system. If the insulation fails, it is possible that death or severe injury can occur as a result of smoke and fire.

• Use a monitoring device that signals an insulation fault.

• Correct the fault as quickly as possible so the motor insulation is not overloaded.

Inadequate ventilation clearances can cause overheating of components with subsequent fire and smoke. This can cause severe injury or even death. This can also result in increased downtime and reduced service lives for devices/systems.

• Ensure compliance with the specified minimum clearance as ventilation clearance for

the respective component.

Missing or illegible warning labels can result in accidents involving death or serious injury.

• Check that the warning labels are complete based on the documentation.

• Attach any missing warning labels to the components, in the national language if

necessary.

• Replace illegible warning labels.

Power Modules PM240 Hardware Installation Manual, 07/2016, A5E36985441C AA

Fundamental safety instructions

NOTICE

Device damage caused by incorrect voltage/insulation tests

WARNING

Danger to life when safety functions are inactive

Note Important safety notices for Safety Integrated functions

If you want to use Safety Integrated functions, you must observe the safety notices in the Safety Integrated manuals.

2.1 General safety instructions

Incorrect voltage/insulation tests can damage the device.

• Before carrying out a voltage/insulation check of the system/machine, disconnect the devices as all converters and motors have been subject to a high voltage test by the manufacturer, and therefore it is not necessary to perform an additional test within the system/machine.

Safety functions that are inactive or that have not been adjusted accordingly can cause operational faults on machines that could lead to serious injury or death.

• Observe the information in the appropriate product documentation before commissioning.

• Carry out a safety inspection for functions relevant to safety on the entire system, including all safety-related components.

• Ensure that the safety functions used in your drives and automation tasks are adjusted and activated through appropriate parameterizing.

• Perform a function test.

• Only put your plant into live operation once you have guaranteed that the functions

relevant to safety are running correctly.

Power Modules PM240

14 Hardware Installation Manual, 07/2016, A5E36985441C AA

Fundamental safety instructions

2.2

Safety instructions for electromagnetic fields (EMF)

WARNING

Danger to life from electromagnetic fields

2.3

Handling electrostatic sensitive devices (ESD)

NOTICE

Damage through electric fields or electrostatic discharge

2.2 Safety instructions for electromagnetic fields (EMF)

Electromagnetic fields (EMF) are generated by the operation of electrical power equipment such as transformers, converters or motors.

People with pacemakers or implants are at a special risk in the immediate vicinity of these devices/systems.

• Ensure that the persons involved are the necessary distance away (minimum 2 m).

Electrostatic sensitive devices (ESD) are individual components, integrated circuits, modules or devices that may be damaged by either electric fields or electrostatic discharge.

Electric fields or electrostatic discharge can cause malfunctions through damaged individual components, integrated circuits, modules or devices.

• Only pack, store, transport and send electronic components, modules or devices in their

original packaging or in other suitable materials, e.g conductive foam rubber of aluminum foil.

• Only touch components, modules and devices when you are grounded by one of the

following methods: – Wearing an ESD wrist strap – Wearing ESD shoes or ESD grounding straps in ESD areas with conductive flooring

• Only place electronic components, modules or devices on conductive surfaces (table

with ESD surface, conductive ESD foam, ESD packaging, ESD transport container).

Power Modules PM240 Hardware Installation Manual, 07/2016, A5E36985441C AA

Fundamental safety instructions

2.4

Industrial security

Note Industrial security

Siemens provides products and solutions with industrial security functions that support the secure operation of plants, solutions, machines, equipment and/or networks. They are important components in a holistic industrial security concept. With this in mind, Siemens’ products and solutions undergo continuous development. Siemens recommends strongly that you regularly check for product updates.

For the secure operation of Siemens preventive action (e.g. cell protection concept) and integrate each component into a holistic, state also be co (

To stay informed about product updates as they occur, sign up for a prod newsletter. For more information, visit this address (

WARNING

Danger as a result of unsafe operating states resulting from software manipulation

WARNING

Danger to life due to software manipulation when using exchangeable storage media

2.4 Industrial security

products and solutions, it is necessary to take suitable

-of-the-art industrial security concept. Third-party products that may be in use should nsidered. For more information about industrial security, visit this address

http://www.siemens.com/industrialsecurity).

uct-specific

http://support.automation.siemens.com

Software manipulation (e.g. by viruses, Trojan horses, malware, worms) can cause unsafe operating states to develop in your installation which can result in death, severe injuries and/or material damage.

• Keep the software up to date. You will find relevant information and newsletters at this address

(http://support.automation.siemens.com).

• Incorporate the automation and drive components into a holistic, state-of-the-art industrial security concept for the installation or machine.

You will find further information at this address (http://www.siemens.com/industrialsecurity).

• Make sure that you include all installed products into the holistic industrial security concept.

Storing files onto exchangeable storage media amounts to an increased risk of infection, e.g. with viruses and malware. As a result of incorrect parameterization, machines can malfunction, which in turn can lead to injuries or death.

• Protect files stored on exchangeable storage media from malicious software by taking suitable protection measures, e.g. virus scanners.

Power Modules PM240

16 Hardware Installation Manual, 07/2016, A5E36985441C AA

Fundamental safety instructions

2.5

Residual risks of power drive systems

2.5 Residual risks of power drive systems

When assessing the machine- or system-related risk in accordance with the respective local regulations (e.g., EC Machinery Directive), the machine manufacturer or system installer must take into account the following residual risks emanating from the control and drive components of a drive system:

1. Unintentional movements of driven machine or system components during commissioning, operation, maintenance, and repairs caused by, for example,

– Hardware and/or software errors in the sensors, control system, actuators, and cables

and connections

– Response times of the control system and of the drive

– Operation and/or environmental conditions outside the specification

– Condensation/conductive contamination

– Parameterization, programming, cabling, and installation errors

– Use of wireless devices/mobile phones in the immediate vicinity of electronic

components

– External influences/damage

– X-ray, ionizing radiation and cosmic radiation

2. Unusually high temperatures, including open flames, as well as emissions of light, noise, particles, gases, etc., can occur inside and outside the components under fault conditions caused by, for example:

– Component failure

– Software errors

– Operation and/or environmental conditions outside the specification

– External influences/damage

3. Hazardous shock voltages caused by, for example:

– Component failure

– Influence during electrostatic charging

– Induction of voltages in moving motors

– Operation and/or environmental conditions outside the specification

– Condensation/conductive contamination

– External influences/damage

4. Electrical, magnetic and electromagnetic fields generated in operation that can pose a risk to people with a pacemaker, implants or metal replacement joints, etc., if they are too close

5. Release of environmental pollutants or emissions as a result of improper operation of the system and/or failure to dispose of components safely and correctly

For more information about the residual risks of the drive system components, see the relevant sections in the technical user documentation.

Power Modules PM240 Hardware Installation Manual, 07/2016, A5E36985441C AA

Fundamental safety instructions

2.5 Residual risks of power drive systems

Power Modules PM240

18 Hardware Installation Manual, 07/2016, A5E36985441C AA

3.1

PM240 Power Modules

Overview

•

0.37

•

2.2

•

7.5

•

18.5

•

37 kw

•

160

Permissible power range of the motors

Control Units for the PM240 Power Modules

The PM240 Power Modules belong to the modular family of SINAMICS G120 inverters. A modular inverter comprises Control Unit and Power Module.

The PM240 Power Modules are designed for line voltages of 3 AC 380 V … 480 V. Depending on the power rating, they are supplied in frame sizes FSA … FSGX.

FSA

kW … 1.5 kW

FSB

FSC

FSD

FSE

FSF

FSGX

The power data refer to Low Overload operation.

Overload capability of the inverter (Page 63)

For the Power Modules, induction motors are permissible in the range from 25 % … 150 % of the inverter power without any restrictions.

You can operate the Power Modules with one of the following Control Units.

● CU230P-2 FSGX from V4.3, all other frame sizes without any restriction

● CU240B-2

kW … 4 kW

kW … 15 kW

kW … 30 kW

… 45 kW

kW … 132 kW

kW … 240 kW

● CU240E

● CU240E-2

● CU240S

● CU250S-2

Power Modules PM240 Hardware Installation Manual, 07/2016, A5E36985441C AA

Introduction

Note Commissioning the inverter

You must first commis the operating instructions of the relevant Control Unit.

3.2

Component specification according to UL

3.2 Component specification according to UL

sion the inverter before you can use it. Commissioning is described in

Overview of the manuals (Page 109)

The components of the SINAMICS G120 product family are UL-certified. The certification is indicated on the products using the UL Listing Mark.

If the inverter is protected using semiconductor fuses, then the fuses must be installed in the same electrical cabinet as the inverter itself.

You can find proof of the certification on the Internet UL certificates (http://www.ul.com) under "Tools / Online Certifications Directory" by entering the file number or the "Name".

The UL file number for the Power Modules of the SINAMICS G120 product family is:

● E121068 for FSA, FSB and FSC

● E192450 for FSD, FSE, FSF and FSGX

Power Modules PM240

20 Hardware Installation Manual, 07/2016, A5E36985441C AA

4.1

Installation conditions

General installation conditions

Inverters for systems in the United States / Canada (UL/cUL)

When installing the Power Modules carefully observe the conditions listed below in order to guarantee reliable, continuous and disturbance-free operation.

● The Power Modules are designed for installation in a control cabinet.

● The Power Modules are certified for use in environments with degree of pollution 2

without condensation; i.e. in environments where no conductive pollution/dirt occurs. Condensation is not permissible.

● Built-in units FSA … FSC have degree of protection IP20.

● Built-in units FSD … FSF have degree of protection IPxxB.

● Devices with push-through technology have degree of protection IP20, to the rear of the

control cabinet, IP55.

● You can find the permissible terminal cross-sections in:

Cable cross-sections and tightening torques (Page 64) .

● The following section describes how you can install the Power Modules in compliance with EMC regulations:

EMC-compliant installation of a plant or machine (Page 22).

● For configurations in conformance with UL/cUL, use the UL/cUL-approved fuses, Class J or Siemens 3NE1 semiconductor fuses, which are specified in this manual.

Permissible fuse types and characteristic values:

● Only use copper cables for 75 °C for frame sizes FSA ... FSC.

● Only use copper cables rated for 60 °C or 75 °C for frame sizes FSD ... FSGX.

● The integrated solid state short circuit protection does not provide cable protection. On

the system side, provide cable protection in conformance with NEC or CEC, Part 1 and the local regulations.

● The inverter features internal motor overload protection corresponding to UL508C. The protection threshold is 115 % of the inverter full load current. When commissioning, you can adapt the motor overload protection using parameter p0640.

Technical data (Page 61).

Power Modules PM240 Hardware Installation Manual, 07/2016, A5E36985441C AA

Installing/mounting

4.2

EMC-compliant installation of a plant or machine

4.2.1

Control cabinet

EMC zones within the control cabinet

4.2 EMC-compliant installation of a plant or machine

The inverter is designed for operation in industrial environments where high-level electromagnetic fields are to be expected.

Reliable and disturbance-free operation of the inverter is only ensured if the inverter is installed in compliance with EMC regulations.

● Subdivide the control cabinet and the machine or plant into EMC zones:

Image 4-1 Example of the EMC zones of a plant or machine

– Zone A: Line supply connection

– Zone B: Power electronics

Devices in Zone B generate energy-rich electromagnetic fields.

– Zone C: Control and sensors

Devices in Zone C do not generate any energy-rich electromagnetic fields themselves, but their functions can be impaired by electromagnetic fields.

– Zone D: Motors, braking resistors outside the control cabinet

Devices in Zone D generate electromagnetic fields with a significant amount of energy

Power Modules PM240

22 Hardware Installation Manual, 07/2016, A5E36985441C AA

Installing/mounting

Control cabinet assembly

4.2 EMC-compliant installation of a plant or machine

● Electromagnetically uncouple the zones from each other by means of one of the following actions:

– Side clearance ≥ 25 cm

– Separate metal enclosure

– Large-area partition plates

● Assign the various devices to zones in the control cabinet.

● Route cables of various zones in separate cable harnesses or cable ducts.

● Install filters or isolation amplifiers at the interfaces of the zones.

● Connect the door, side panels, top and base plate of the control cabinet with the control

cabinet frame using one of the following methods:

– Electrical contact surface of several cm² for each contact location

– Several screw connections

– Short, finely stranded, braided copper wires with cross-sections

≥ 95 mm² / 000 (3/0) (-2) AWG

● Install a shield support for shielded cables that are routed out of the control cabinet.

● Connect the PE bar and the shield support to the control cabinet frame through a large

surface area to establish a good electrical connection.

● Mount the control cabinet components on a bare metal mounting plate.

● Connect the mounting plate to the control cabinet frame and PE bar and shield support

through a large surface area to establish a good electrical connection.

● For screw connections onto painted or anodized surfaces, establish a good conductive contact using one of the following methods:

– Use special (serrated) contact washers that cut through the painted or anodized

surface.

– Remove the insulating coating at the contact locations.

Power Modules PM240 Hardware Installation Manual, 07/2016, A5E36985441C AA

Installing/mounting

Measures required for several control cabinets

Further information

4.2 EMC-compliant installation of a plant or machine

● Install equipotential bonding for all control cabinets.

● Screw the frames of the control cabinets together at several locations through a large

surface area using serrated washers to establish a good electrical connection.

● In plants and systems where the control cabinets are lined up next to one another, and which are installed in two groups back to back, connect the PE bars of the two cabinet groups at as many locations as possible.

Image 4-2 Grounding and high-frequency equipotential bonding measures in the control cabinet

and in the plant/system

Additional information about EMC-compliant installation is available in the Internet:

EMC installation guideline (http://support.automation.siemens.com/WW/view/en/60612658)

Power Modules PM240

24 Hardware Installation Manual, 07/2016, A5E36985441C AA

Installing/mounting

4.2.2

Cables

Cable routing inside the cabinet

4.2 EMC-compliant installation of a plant or machine

Cables with a high level of interference and cables with a low level of interference are connected to the inverter:

● Cables with a high level of interference:

– Cable between the line filter and inverter

– Motor cable

– Cable at the inverter DC link connection

– Cable between the inverter and braking resistor

● Cables with a low level of interference:

– Cable between the line and line filter

– Signal and data cables

● Route the power cables with a high level of interference so that there is a minimum

clearance of 25 cm to cables with a low level of interference.

If the minimum clearance of 25 cm is not possible, insert separating metal sheets between the cables with a high level of interference and cables with a low level of interference. Connect these separating metal sheets to the mounting plate to establish a good electrical connection.

● Cables with a high level of interference and cables with a low level of interference may

only cross over at right angles:

● Keep all of the cables as short as possible.

● Route all of the cables close to the mounting plates or cabinet frames.

● Route signal and data cables - as well as the associated equipotential bonding cables -

parallel and close to one another.

● Twist incoming and outgoing unshielded individual conductors.

Alternatively, you can route incoming and outgoing conductors in parallel, but close to one another.

● Ground any unused conductors of signal and data cables at both ends.

● Signal and data cables must only enter the cabinet from one side, e.g. from below.

● Using shielded cables for the following connections:

– Cable between the inverter and line filter

– Cable between the inverter and output reactor or sine-wave filter

Power Modules PM240 Hardware Installation Manual, 07/2016, A5E36985441C AA

Installing/mounting

Routing cables outside the control cabinet

4.2 EMC-compliant installation of a plant or machine

Image 4-3 Routing inverter cables inside and outside a control cabinet

● Maintain a minimum clearance of 25 cm between cables with a high level of interference and cables with a low level of interference.

● Using shielded cables for the following connections:

– Inverter motor cable

– Cable between the inverter and braking resistor

– Signal and data cables

● Connect the motor cable shield to the motor enclosure using a PG gland that establishes a good electrical connection.

Power Modules PM240

26 Hardware Installation Manual, 07/2016, A5E36985441C AA

Installing/mounting

Requirements relating to shielded cables

4.2.3

Electromechanical components

Radio interference suppression

4.2 EMC-compliant installation of a plant or machine

● Use cables with finely-stranded, braided shields.

● Connect the shield to at least one end of the cable.

Image 4-4 Examples for EMC-compliant shield support

● Attach the shield to the shield support directly after the cable enters the cabinet.

● Do not interrupt the shield.

● Only use metallic or metallized plug connectors for shielded data cables.

● Connect interference suppression elements to the following components:

– Coils of contactors

– Relays

– Solenoid valves

– Motor holding brakes

● Connect the interference suppression element directly at the coil.

● Use RC elements or varistors for AC-operated coils and freewheeling diodes or varistors

for DC-operated coils.

Power Modules PM240 Hardware Installation Manual, 07/2016, A5E36985441C AA

Installing/mounting

4.3

Power losses and air cooling requirements

Cooling requirements

•

Total of the power losses of the individual components.

•

Permissible temperature rise in the electrical cabinet

Measures in order to ensure that the components are adequately cooled

4.3 Power losses and air cooling requirements

Depending on the power loss of the individual components, the control cabinet will require a cooling airflow to prevent the components from overheating.

Formula for calculating the cooling airflow:

Power loss:

Δ T

1. Add the power losses of the individual components.

– Power Module data:

– The Control Unit power loss is less than 0.04 kW.

– Use the manufacturers data for components, for example reactors or filters

2. Calculate the air flow required, using the formula above.

3. Ensure that the control cabinet is appropriately ventilated and equipped with suitable air filters.

4. Ensure that the components have the specified clearances with respect to one another.

5. Ensure that the components are provided with adequate cooling air through the cooling openings.

6. Use the appropriate air barriers to prevent cooling air short circuits

"Technical data (Page 61)".

Power Modules PM240

28 Hardware Installation Manual, 07/2016, A5E36985441C AA

Installing/mounting

4.3 Power losses and air cooling requirements

Image 4-5 Air barriers for avoiding cooling air short circuits

Power Modules PM240 Hardware Installation Manual, 07/2016, A5E36985441C AA

Installing/mounting

4.4

Mounting the Power Modules

Protection against the spread of fire

Protection against condensation or electrically conductive contamination

Installing Power Modules

4.4 Mounting the Power Modules

The device may be operated only in closed housings or in control cabinets with protective covers that are closed, and when all of the protective devices are used. The installation of the device in a metal control cabinet or the protection with another equivalent measure must prevent the spread of fire and emissions outside the control cabinet.

Protect the device, e.g. by installing it in a control cabinet with degree of protection IP54 according to IEC 60529 or NEMA 12. Further measures may be necessary for particularly critical operating conditions.

If condensation or conductive pollution can be excluded at the installation site, a lower degree of control cabinet protection may be permitted.

The following is required to correctly install a Power Module:

● Install the Power Module vertically with the motor connections facing downwards.

● Comply with the installation regulations specified in the following sections:

– Minimum clearances to other components

– Fixing elements

– Tightening torques for fixing elements

Power Modules PM240

30 Hardware Installation Manual, 07/2016, A5E36985441C AA

+ 90 hidden pages

Siemens Sinamics G120,PM240 Hardware Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Power Modules PM240

Table of contents

General safety instructions

Handling electrostatic sensitive devices (ESD)

2.2 Safety instructions for electromagnetic fields (EMF)

2.4 Industrial security

2.5 Residual risks of power drive systems

PM240 Power Modules

3.2 Component specification according to UL

Installation conditions

Control cabinet

4.2 EMC-compliant installation of a plant or machine

Cables

Electromechanical components

4.3 Power losses and air cooling requirements

4.4 Mounting the Power Modules