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Sinamics GM150 6SL3835-2LN44-2AA0
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Siemens Sinamics GM150 6SL3835-2LN44-2AA0 Operating And Installation Instructions

www.siemens.com/drives
This documentation pertains to
Operating Instructions Installation Instructions
Medium-Voltage Drive
SINAMICS GM150
Type 6SL3835-2LN44-2AA0
Edition 10/2019
28.10.2019 12:50 V32.00
Medium-Voltage Drive
SINAMICS GM150 Type 6SL3835-2LN44-2AA0
This documentation pertains to MUSTER
Introduction
1
Operating Instructions Installation Instructions
Safety instructions
Description
Preparations for use
Installation
Electrical connection
Start-up
Operation
2
3
4
5
6
7
8
Maintenance
Spare parts
Disposal
Service & Support
Technical data and drawings
Checklists and forms
9
10
11
A
B
C
Edition 10/2019
Legal information Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
indicates that minor personal injury can result if proper precautions are not taken.
NOTICE indicates that property damage can result if proper precautions are not taken.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property damage.
Qualified Personnel
The product/system described in this documentation may be operated only by personnel qualified for the specific task in accordance with the relevant documentation, in particular its warning notices and safety instructions. Qualified personnel are those who, based on their training and experience, are capable of identifying risks and avoiding potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical documentation. If products and components from other manufacturers are used, these must be recommended or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and maintenance are required to ensure that the products operate safely and without any problems. The permissible ambient conditions must be complied with. The information in the relevant documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in this publication is reviewed regularly and any necessary corrections are included in subsequent editions.
Siemens AG Large Drives Applications Vogelweiherstr. 1-15 90441 NÜRNBERG GERMANY
Document order number: 0009990025-038352 Ⓟ 10/2019 Subject to change
Copyright © Siemens AG 2018 - 2019. All rights reserved

Table of contents

1 Introduction.................................................................................................................................................15
1.1 About these instructions.........................................................................................................15
2 Safety instructions ......................................................................................................................................17
2.1 Warning symbol on the device ...............................................................................................17
2.2 Qualified personnel ................................................................................................................17
2.3 The 5 safety rules...................................................................................................................17
2.4 Safe handling .........................................................................................................................18
2.5 Electromagnetic fields in electrical power engineering installations ......................................21
2.6 Components that can be destroyed by electrostatic discharge (ESD)...................................21
2.7 Information for nominated persons in control of an electrical installation...............................22
2.7.1 Proper usage..........................................................................................................................22
2.7.2 Grounding concept.................................................................................................................24
2.7.3 Installation site safety.............................................................................................................24
2.7.4 Measures for operator protection in electromagnetic fields ...................................................25
2.8 Residual risks.........................................................................................................................25
2.9 Security information ...............................................................................................................27
3 Description..................................................................................................................................................29
3.1 Applications............................................................................................................................29
3.2 Safety concept .......................................................................................................................29
3.2.1 Safety components and functions..........................................................................................29
3.2.2 External safety components...................................................................................................30
3.2.3 Protection and monitoring functions of internal components .................................................30
3.2.4 Protection and monitoring functions for external components ...............................................31
3.3 Design ....................................................................................................................................31
3.3.1 Components...........................................................................................................................31
3.3.2 Design of the Basic Line Module............................................................................................32
3.3.3 Design of the Motor Module...................................................................................................33
3.3.4 Gating.....................................................................................................................................34
3.4 Operating principle .................................................................................................................34
3.5 Description of the components...............................................................................................35
3.5.1 SINAMICS Control Unit..........................................................................................................35
3.5.2 Power Stack Adapter .............................................................................................................35
3.5.3 Terminal Modules...................................................................................................................36
3.5.4 Precharging............................................................................................................................37
3.5.5 Electromechanical door interlock system...............................................................................37
3.5.6 Make-proof grounding switch.................................................................................................38
3.5.7 Circuit-breaker (provided by the customer)............................................................................38
3.5.8 Converter transformer............................................................................................................38
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3.5.9 Actual value acquisition..........................................................................................................39
3.5.10 Common power supply ..........................................................................................................40
3.5.10.1 Field of application .................................................................................................................40
3.5.10.2 Design ....................................................................................................................................40
3.5.10.3 Connections ...........................................................................................................................41
3.5.11 DM10 diagnostics module......................................................................................................42
3.5.11.1 Functions................................................................................................................................42
3.5.11.2 Signal processing...................................................................................................................43
3.5.11.3 Voltage monitoring .................................................................................................................44
3.5.12 Re-cooling unit ......................................................................................................................45
3.5.12.1 Re-cooling unit requirements .................................................................................................45
3.5.12.2 Operating principle of the re-cooling unit ...............................................................................45
3.5.12.3 The internal deionized water circuit........................................................................................46
3.5.13 Customer terminal strips ........................................................................................................46
3.6 Description of options.............................................................................................................47
3.6.1 NAMUR terminal strip (option B00)........................................................................................47
3.6.2 Auxiliary voltage supply 3 AC 200 V 50 Hz (option C30).......................................................47
3.6.3 Suitable for marine use with individual certificate from Lloyds Register (LR) (option E21)......47
3.6.4 Isolation amplifiers for optional analog inputs (option E86)....................................................48
3.6.5 Isolation amplifiers for optional analog outputs (option E87) .................................................48
3.6.6 CAN bus interface (option G20).............................................................................................48
3.6.7 Modbus RTU Slave interface (option G22) ............................................................................49
3.6.8 1x temperature sensor evaluation unit TM150 (option G51)..................................................49
3.6.9 Additional Terminal Module TM31 (option G61) ....................................................................49
3.6.10 Additional Terminal Module TM15 (option G63) ....................................................................50
3.6.11 PADU8 diagnosis module (option G66) .................................................................................50
3.6.12 Indicator lamps in the cabinet door (option K20)....................................................................50
3.6.13 Display instruments in the cabinet door for voltage, current, speed, and output plus
indicator lamps (option K21) ..................................................................................................51
3.6.14 Sensor Module SMC30 (option K50) .....................................................................................51
3.6.15 CU320-2 DP Control Unit (option K90) ..................................................................................51
3.6.16 dv/dt filter (option L10) ...........................................................................................................52
3.6.17 Automatic restart function (option L32) ..................................................................................53
3.6.18 Line-side grounding switch (option L48) ................................................................................54
3.6.19 Motor-side grounding switch (option L49) ..............................................................................54
3.6.20 Cabinet illumination and service socket in closed-loop control unit (option L50) ...................54
3.6.21 Disconnector at the drive output (option L51) ........................................................................54
3.6.22 Circuit breaker at the drive output (option L52)......................................................................55
3.6.23 Uninterruptible power supply (UPS) (option L53)...................................................................55
3.6.24 Anti-condensation heating (option L55) .................................................................................55
3.6.25 EMERGENCY STOP Category 1 (option L60) ......................................................................55
3.6.26 Braking Module (option L72) ..................................................................................................56
3.6.27 Safety locking system (option M10) .......................................................................................57
3.6.28 Power cable connection at the drive input from above (option M13) .....................................57
3.6.29 Signal and control cable (max. 2.5 mm²) (option M32) ..........................................................57
3.6.30 IP54 degree of protection (option M54)..................................................................................57
3.6.31 Redundant fan in the power unit (option M61) .......................................................................57
3.6.32 Suitability for marine use (option M66)...................................................................................58
3.6.33 Controlled outgoing circuit for auxiliary equipment 400 V 3 AC (option N30) .......................58
3.6.34 Sine-wave filter (option Y15) ..................................................................................................59
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4 Preparations for use ...................................................................................................................................61
4.1 Requirements for installation location ....................................................................................61
4.2 Inspections when receiving the delivery.................................................................................61
4.2.1 Scope of delivery....................................................................................................................61
4.2.2 Checking shock and tilt indicators..........................................................................................62
4.2.3 Checking the load handling attachments ...............................................................................63
4.3 Transportation ........................................................................................................................64
4.3.1 Transport markings ................................................................................................................64
4.3.2 Transport requirements..........................................................................................................64
4.3.3 Observe center of gravity.......................................................................................................65
4.3.4 Transport with a fork-lift truck.................................................................................................65
4.3.5 Transport with a crane ...........................................................................................................66
4.3.6 Using lifting rods.....................................................................................................................66
4.3.7 Transporting transportation units packed in boxes ................................................................68
4.4 Unpacking ..............................................................................................................................69
4.4.1 Removing the packaging........................................................................................................69
4.4.2 Removing load securing devices ...........................................................................................70
4.4.3 Lifting the cabinet off the transport pallet ...............................................................................70
4.4.4 Opening doors in preparation for use.....................................................................................71
4.4.5 Checking the shock and tilt indicators inside the cabinet.......................................................72
4.5 Storage...................................................................................................................................72
4.5.1 Emptying the drive .................................................................................................................72
4.5.2 Storing a device .....................................................................................................................73
5 Installation ..................................................................................................................................................75
5.1 Safety instructions for assembly ............................................................................................75
5.2 Tools required ........................................................................................................................76
5.3 Preparations...........................................................................................................................76
5.3.1 Remove the rear panel...........................................................................................................76
5.3.2 Mounting the side panels .......................................................................................................76
5.4 Screwing the transport units together ....................................................................................78
5.5 Connecting to the foundation .................................................................................................78
5.6 Connecting the grounding bars ..............................................................................................79
5.7 Connecting the DC bus ..........................................................................................................80
5.8 Connecting the interface terminals.........................................................................................83
5.9 Connecting the water circuits .................................................................................................83
5.10 Installing the battery of the uninterruptible power supply .......................................................84
6 Electrical connection...................................................................................................................................87
6.1 Safety instructions for electrical connections .........................................................................87
6.2 Electromagnetic compatibility.................................................................................................89
6.3 Potential concept....................................................................................................................92
6.4 Electrical requirements...........................................................................................................92
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6.5 Connection .............................................................................................................................93
6.5.1 Manually unlocking power-unit doors.....................................................................................93
6.5.2 Connecting ground.................................................................................................................93
6.5.3 Preparations for connecting the power cables.......................................................................94
6.5.4 Connecting power cables.......................................................................................................94
6.5.5 Connect the power cable to the motor and the supply system ..............................................95
6.5.6 Connect the auxiliary voltage.................................................................................................97
6.5.7 Connecting the encoder to the SMC30 Sensor Module.........................................................97
6.5.8 Interconnecting optional connections.....................................................................................99
6.5.9 Connecting the re-cooling unit to the drive.............................................................................99
6.5.10 Fastening the cable ducts with cable ties...............................................................................99
6.6 Mounting the rear panel .........................................................................................................99
7 Start-up ....................................................................................................................................................101
7.1 Description and configuration of the PROFIBUS interface ..................................................101
7.1.1 PROFIBUS interface, diagnostics LEDs, address switches.................................................102
7.1.2 Connecting PROFIBUS cables ............................................................................................104
7.1.3 Setting the PROFIBUS address...........................................................................................105
7.1.4 Requirements for communication via PROFIBUS ...............................................................106
8 Operation..................................................................................................................................................107
8.1 Safety instructions for operation...........................................................................................107
8.2 Operating the drive...............................................................................................................108
8.3 Operation via the AOP30 operator panel .............................................................................108
8.3.1 General information about the AOP30 operator panel.........................................................108
8.3.1.1 AOP30 operator panel .........................................................................................................108
8.3.1.2 Buttons of the AOP30 ..........................................................................................................110
8.3.1.3 Basic operation of the AOP 30.............................................................................................110
8.3.2 Configuration of the AOP30 operator panel.........................................................................113
8.3.2.1 Define operation screen .......................................................................................................113
8.3.2.2 Control settings ....................................................................................................................117
8.3.2.3 Inhibit functions ....................................................................................................................120
8.3.3 Menu description and setting options...................................................................................122
8.3.3.1 Operation screen..................................................................................................................122
8.3.3.2 Parameterization ..................................................................................................................125
8.3.3.3 Fault/alarm memory .............................................................................................................127
8.3.3.4 Commissioning / service device commissioning ..................................................................129
8.3.3.5 Commissioning / service drive commissioning.....................................................................133
8.3.3.6 Commissioning / Service - AOP settings .............................................................................134
8.3.3.7 Commissioning / Service - AOP diagnostics........................................................................138
8.3.3.8 Language .............................................................................................................................142
8.4 Parameter ............................................................................................................................142
8.4.1 Parameters...........................................................................................................................142
8.4.2 Parameter types...................................................................................................................143
8.5 Functions..............................................................................................................................144
8.5.1 Setpoint channel and closed-loop control ............................................................................144
8.5.1.1 Setpoint channel ..................................................................................................................144
8.5.1.2 Vector control .......................................................................................................................147
8.5.1.3 U/f control.............................................................................................................................150
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8.5.2 Analog and digital inputs/outputs .........................................................................................151
8.5.2.1 Analog outputs .....................................................................................................................151
8.5.2.2 Additional settings for analog outputs ..................................................................................153
8.5.2.3 Scaling the input signal of the analog inputs........................................................................156
8.5.2.4 Digital inputs/outputs............................................................................................................157
8.5.2.5 Digital outputs ......................................................................................................................158
8.5.3 Monitoring functions and protective functions......................................................................159
8.5.3.1 Insulation monitoring ............................................................................................................160
8.5.3.2 Tripping of the circuit-breaker in case of undervoltage ........................................................161
8.5.3.3 DC-link short-circuiter...........................................................................................................161
8.5.3.4 Vdc-max closed-loop control................................................................................................162
8.5.3.5 Speed monitoring with incremental encoder ........................................................................164
8.5.3.6 Controlled stop, EMERGENCY STOP category 1 ...............................................................164
8.5.3.7 Automatic restart ..................................................................................................................164
8.6 Fault and system messages ................................................................................................166
8.6.1 External alarms and faults....................................................................................................166
8.6.2 Message from the grounding switch ....................................................................................166
8.6.3 Diagnosis .............................................................................................................................167
8.6.3.1 Indicating and rectifying faults..............................................................................................167
8.6.3.2 Diagnostics via LEDs ...........................................................................................................168
8.6.3.3 Diagnostics via parameters..................................................................................................169
9 Maintenance .............................................................................................................................................175
9.1 Safety instructions for maintenance .....................................................................................175
9.2 Grounding the system ..........................................................................................................177
9.2.1 Grounding with a grounding device......................................................................................177
9.2.2 Grounding using a make-proof grounding switch.................................................................180
9.3 Opening the doors................................................................................................................181
9.3.1 Opening the power unit doors for maintenance work...........................................................181
9.3.2 Manually unlocking power unit doors...................................................................................182
9.3.3 Secure locking system (option M10)....................................................................................183
9.4 Inspection and maintenance ................................................................................................184
9.4.1 Inspection.............................................................................................................................184
9.4.2 Checklist...............................................................................................................................184
9.4.3 Cleaning...............................................................................................................................185
9.4.3.1 Cleaning aluminum parts .....................................................................................................186
9.4.4 Visual inspections ................................................................................................................186
9.4.4.1 Equipment for visual inspections..........................................................................................186
9.4.4.2 Checking hoisting solenoids and security bolts....................................................................186
9.4.4.3 Checking the isolating clearances........................................................................................186
9.4.4.4 Checking the capacitor release............................................................................................187
9.4.4.5 Checking the cable and screw terminals..............................................................................187
9.4.4.6 Checking the plug connections. ...........................................................................................187
9.4.5 Replacing filter mats.............................................................................................................188
9.4.6 Replacing the filter mats in the roof assembly .....................................................................188
9.4.7 Maintaining the fan...............................................................................................................189
9.4.8 Load operator panel firmware, parameter and signal descriptions ......................................190
9.4.9 Replacing the back-up battery of the AOP30 operator panel ..............................................190
9.5 Repair...................................................................................................................................192
9.5.1 Torques................................................................................................................................193
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9.5.2 Replacing the AVT combination module..............................................................................194
9.5.3 Replacing the operator panel...............................................................................................195
9.5.4 Replacing the CompactFlash card.......................................................................................196
9.5.5 Replacing the phase module or diode module.....................................................................196
9.5.5.1 Attaching the changing device to the stacker.......................................................................196
9.5.5.2 Replacing the phase module................................................................................................198
9.5.5.3 Replacing the diode module.................................................................................................205
9.5.6 Replacing the Power Stack Adapter ....................................................................................209
9.5.7 Replace the sponge for the leak detector ............................................................................210
9.5.8 Replacing fuses....................................................................................................................211
9.5.9 Replacing the current transformer........................................................................................212
9.5.10 Door interlock system...........................................................................................................212
9.5.11 Replacing the precharging transformer................................................................................212
9.5.12 Replacing the precharging rectifier ......................................................................................214
10 Spare parts ...............................................................................................................................................215
11 Disposal....................................................................................................................................................217
11.1 Disposing of packaging material ..........................................................................................217
11.2 Removing device components and old devices ...................................................................217
A Service & Support.....................................................................................................................................219
B Technical data and drawings....................................................................................................................221
B.1 Technical specifications .......................................................................................................221
B.1.1 Standards and regulations ...................................................................................................221
C Checklists and forms ................................................................................................................................223
C.1 Mechanical installation: Checklist ........................................................................................223
C.2 Checklist for electrical installation ........................................................................................224
Index.........................................................................................................................................................229
Tables
Table 3-1 Deionized water requirements.....................................................................................................46
Table 3-2 Braking power of the Braking Module with external braking resistor...........................................56
Table 3-3 Max. permissible cable lengths ...................................................................................................59
Table 6-1 Dimensioning cables ...................................................................................................................92
Table 6-2 Cable cross-sections...................................................................................................................93
Table 6-3 Drive and motor connection terminals.........................................................................................96
Table 7-1 PROFIBUS interface X126........................................................................................................103
Table 7-2 Description of the COM LED.....................................................................................................103
Table 8-1 List of signals for the operation screen......................................................................................115
Table 8-2 Scaling.......................................................................................................................................117
Table 8-3 Overview of important parameters (equipment commissioning) ...............................................131
Table 8-4 Drive Object VectorMV..............................................................................................................133
Table 8-5 Parameter..................................................................................................................................145
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Table 8-6 Parameter..................................................................................................................................145
Table 8-7 Parameter..................................................................................................................................146
Table 8-8 Parameter..................................................................................................................................147
Table 8-9 LEDs of the Power Stack Adapters ..........................................................................................168
Table 8-10 LEDs of the DM10 diagnostics module .....................................................................................169
Table 9-1 Technical specifications of the backup battery..........................................................................190
Table 9-2 Tightening torque for screws.....................................................................................................193
Table 9-3 Tightening torques for screw terminals for copper cables without cable lug 1).........................193
Table B-1 Standards and conformity .........................................................................................................221
Figures
Figure 2-1 ESD information ..........................................................................................................................22
Figure 3-1 Design of the power unit..............................................................................................................32
Figure 3-2 Basic Line Module with diodes in 12-pulse configuration............................................................33
Figure 3-3 Phase module .............................................................................................................................34
Figure 3-4 Overview of PSA interfaces.........................................................................................................36
Figure 3-5 AVT combination module ............................................................................................................40
Figure 3-6 Design when using IGCTs...........................................................................................................40
Figure 3-7 Overview ....................................................................................................................................41
Figure 3-8 Schematic diagram: Printed circuit board of the diagnostics module..........................................42
Figure 3-9 Logical design of the DM10 diagnosis module............................................................................43
Figure 3-10 Circuit diagram option L10 ..........................................................................................................52
Figure 3-11 Connecting the motor to the dv/dt filter .......................................................................................53
Figure 3-12 Connecting the motor to the sine-wave filter...............................................................................59
Figure 4-1 Example of attaching and displaying the shock and tilt indicators ..............................................63
Figure 4-2 Example illustration of centers of gravity.....................................................................................65
Figure 4-3 Lifting bar label............................................................................................................................67
Figure 4-4 Securing the lifting rods...............................................................................................................67
Figure 4-5 Transporting a transportation unit (still in packaging) with a crane .............................................69
Figure 4-6 Example: Label with instructions for opening the doors..............................................................71
Figure 5-1 Connecting the transport units ....................................................................................................77
Figure 5-2 Connecting cabinets....................................................................................................................79
Figure 5-3 Removing the device fuse...........................................................................................................80
Figure 5-4 Removing the dust protection......................................................................................................80
Figure 5-5 Connecting the DC bus ...............................................................................................................82
Figure 5-6 Remove the screws.....................................................................................................................84
Figure 5-7 Install battery...............................................................................................................................85
Figure 6-1 Shield connection using a clip.....................................................................................................91
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Figure 6-2 Bridging shield gaps....................................................................................................................91
Figure 6-3 Potential concept.........................................................................................................................92
Figure 6-4 Grounding lug..............................................................................................................................94
Figure 6-5 Example: Connecting the power cables......................................................................................94
Figure 6-6 Connection of the supply-system power cable............................................................................96
Figure 6-7 Connecting the external encoder to the SMC30 Sensor Module ................................................98
Figure 6-8 Connection example 1: HTL encoder, bipolar, with reference signal..........................................98
Figure 6-9 Schematic diagram: Fastening the cable ties..............................................................................99
Figure 7-1 PROFIBUS interface .................................................................................................................102
Figure 7-2 X126 PROFIBUS connection ....................................................................................................102
Figure 7-3 PROFIBUS address switch cover .............................................................................................104
Figure 7-4 PROFIBUS connectors .............................................................................................................104
Figure 7-5 Position of the bus terminating resistors ...................................................................................105
Figure 8-1 AOP30 operator panel...............................................................................................................109
Figure 8-2 Menu structure of the AOP 30...................................................................................................111
Figure 8-3 Function keys of the AOP 30.....................................................................................................112
Figure 8-4 Example of the operation screen...............................................................................................113
Figure 8-5 Menu structure of the operation screens...................................................................................122
Figure 8-6 Parameterization menu structure ..............................................................................................125
Figure 8-7 Selecting data sets....................................................................................................................126
Figure 8-8 Menu structure for fault memory/alarm memory .......................................................................127
Figure 8-9 Alarm screen .............................................................................................................................129
Figure 8-10 Commissioning / service / device commissioning menu structure ............................................129
Figure 8-11 Commissioning / service / drive commissioning menu structure...............................................133
Figure 8-12 Commissioning /Service / AOP settings menu structure...........................................................134
Figure 8-13 Commissioning / Service / AOP diagnostics menu structure ....................................................138
Figure 8-14 Language menu structure .........................................................................................................142
Figure 8-15 Parameter types........................................................................................................................143
Figure 8-16 Switchover conditions................................................................................................................149
Figure 8-17 Operating areas and characteristic curves for the induction motor with drive supply ...............150
Figure 8-18 Example: Setting analog output 0 .............................................................................................153
Figure 8-19 Potential supply of external signals...........................................................................................157
Figure 8-20 Digital signal output to the system I/O.......................................................................................158
Figure 9-1 Grounding points.......................................................................................................................178
Figure 9-2 Example: Attaching the grounding spider..................................................................................179
Figure 9-3 Attaching the grounding spider..................................................................................................180
Figure 9-4 Make-proof-grounding switch closed.........................................................................................181
Figure 9-5 Principle of the mechanical door interlock.................................................................................183
Figure 9-6 Components of the secure locking system................................................................................183
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Figure 9-7 Example diagram: Replacing filter mats....................................................................................188
Figure 9-8 Changing the filter in the roof assembly....................................................................................189
Figure 9-9 Replacing the backup battery....................................................................................................191
Figure 9-10 Example of an AVT combination module ..................................................................................194
Figure 9-11 Replacing the operator panel ....................................................................................................195
Figure 9-12 Attaching the changing device to the forklift truck.....................................................................197
Figure 9-13 Attaching the changing device to the forklift truck.....................................................................197
Figure 9-14 Lifting solenoid ..........................................................................................................................198
Figure 9-15 Water connection ......................................................................................................................199
Figure 9-16 Fiber-optic conductors and power supply cable........................................................................199
Figure 9-17 Busbar package ........................................................................................................................200
Figure 9-18 Motor current acquisition module ..............................................................................................200
Figure 9-19 Busbar.......................................................................................................................................201
Figure 9-20 Installing the busbars ................................................................................................................201
Figure 9-21 Insulators of the phase module and lifting lugs .........................................................................202
Figure 9-22 Changing device: roller tracks...................................................................................................202
Figure 9-23 Changing device: joining the roller tracks..................................................................................203
Figure 9-24 Changing device: stop brackets ................................................................................................203
Figure 9-25 Diode module: water connection...............................................................................................206
Figure 9-26 Diode module: phase connections ............................................................................................206
Figure 9-27 Diode module: insulators...........................................................................................................207
Figure 9-28 Diode module: lugs....................................................................................................................207
Figure 9-29 Changing device: roller tracks...................................................................................................207
Figure 9-30 Changing device: joining the roller tracks..................................................................................208
Figure 9-31 Changing device: stop brackets ................................................................................................208
Figure 9-32 Sponge......................................................................................................................................210
Figure 9-33 Replacing the sponge................................................................................................................211
Figure 9-34 Example: Replacing the precharging transformer.....................................................................213
Figure 9-35 Replacing the precharging rectifier............................................................................................214
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SINAMICS GM150 6SL3835-2LN44-2AA0
14 Operating Instructions Rev.201910281250 MUSTER

Introduction

1.1 About these instructions

These Operating Instructions describe the device and provide you with information about handling it - from the initial shipment up to disposal. Keep these instructions for later use.
Read these Operating Instructions and comply with the information provided in them. In this way you can ensure safe, problem-free operation and a long service life.
Safety information and handling-related warnings are provided in these Operating Instructions. For your own safety, the safety of other persons and to avoid material damage, carefully follow these instructions when carrying out any work.
If you have suggestions for improving the document, please contact our Service Center (Page 219).
Text format features
You can find the following text format features in these instructions:
1. Handling instructions are always formatted as a numbered list. Always perform the steps in the order given.
● Lists are formatted as bulleted lists.
1
– Lists on the second level are hyphenated.
Note
The note provides you with additional information about the product itself, handling the product
- and the relevant documentation.
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Introduction
1.1 About these instructions
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Safety instructions

In the individual chapters of this document, you will find safety instructions that must be obeyed absolutely, for your own safety, to protect other people and to avoid damage to property. Carefully comply with the following safety instructions when performing all of the activities.

2.1 Warning symbol on the device

Please observe the warning symbols attached to the device. The warning symbols have the following meaning:
Warning symbol Meaning
Warning: Voltage
Warning: Hot surface
General warning symbol: Observe the explanations about the hazard on the device labels.
2
For transportation, observe the "transportation markings (Page 64)" on the device packaging.

2.2 Qualified personnel

The product/system described in this documentation may only be operated by personnel qualified for the specific task in accordance with the relevant documentation for the specific task, in particular its warning notices and safety instructions. Because of their training and experience, qualified personnel can recognize any risks involved with handling these products/ systems and avoid any possible dangers.

2.3 The 5 safety rules

To ensure your own personal safety as well as to avoid material damage, always comply with the safety-relevant instructions when carrying out any work. Also carefully comply with the 5 safety rules according to EN 50110‑1 "Working in a no-voltage state" in the specified sequence.
5 safety rules
1. Disconnect the system. Also disconnect the auxiliary circuits, for example, anti-condensation heating.
2. Secure against reconnection.
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Safety instructions

2.4 Safe handling

3. Verify absence of operating voltage.
4. Ground and short-circuit.
5. Provide protection against adjacent live parts.
To energize the system, apply the measures in reverse order.
2.4 Safe handling
Electric shock from external supplies
Even if the circuit breaker is open, parts of the drive can be under voltage (live) as a result of the auxiliary voltage at the premagnetization, precharging or demagnetization transformers. This danger is not limited to the drive, but can also occur with components that are electrically connected to the drive (e.g. circuit breakers or isolators). Touching live parts can result in death, serious injury and material damage
● Isolate all components that can feed voltage to the drive before commencing work.
Electric shock due to high voltages in operation
When operating this equipment very high voltages develop. Even after switching off the mains voltage, or while the connected machine is still turning, high voltages can remain for a prolonged length of time. High voltages can cause death or serious injury if the safety rules are not observed or if the equipment is handled incorrectly.
● Operate the device properly.
● Always follow the "The five safety rules (Page 17)" when performing any work.
● Service and maintain the device regularly and correctly.
Electric shock if the grounding switch is defective
A grounding switch is a component that has an associated certain probability of failure. This means that it is possible that the feedback signal regarding the switching state no longer matches the actual switching state of the grounding switch. This means that if the power unit door is open, hazardous voltages could still be present at the active parts of the drive. Touching the device can result in death or serious injury.
● Check the function of the grounding switch before carrying out any other work at the drive.
● Carefully comply with the 5 safety rules (Page 17).
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Electric shock due to induced voltage
Rotating machinery can induce dangerous high voltages and synchronous motors that are not de-excited immediately can also pose a hazard. If the connection to the motor is not isolated or grounded, these voltages can also remain. Touching live parts can result in death or serious injury.
● Before opening the doors, wait until the connected machine has come to a standstill.
Electric shock at DC link capacitors
High voltages are still present at the DC link capacitors even after shutdown. Touching live parts can result in death or serious injury.
● A label specifies the discharge times of the DC link capacitors. Only open the doors once these discharge times have elapsed.
● Observe the five safety rules when performing any work.
Electric shock caused by high auxiliary voltages
High auxiliary voltages are still present even after shutdown. Touching live parts can result in death or serious injury.
Safety instructions
2.4 Safe handling
● Observe the five safety rules when performing any work.
Danger due to hazardous arcing
Hazards caused by arcing can occur as result of the following factors, for example:
● The input currents are exceeded.
● Incorrectly dimensioned circuit breaker or transformers.
● Incorrectly connected cables or cables that have not been connected.
● Contamination and dirt.
● Tools that have been forgotten, e.g. when mounting and installing the equipment.
Arcing can result in death, serious injury or material damage.
● Make sure that the system is properly dimensioned and that the power cables are correctly connected. The maximum permissible input currents are listed in the "Technical specifications".
● Remove contamination and dirt.
● After installation and mounting, carefully check that no objects have been left in the device.
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Safety instructions
2.4 Safe handling
Danger due to live stationary parts, moving or rotating parts
Contact with the parts mentioned can result in death, serious physical injury or damage to property.
● Observe the instructions regarding installation and operation.
● Always take protective measures before touching any components.
● Do not remove any covers.
Risk of burns due to hot component surfaces
Certain components (e.g. heat sinks and reactors) can become very hot during operation. These components can remain hot for a long time after operation. Contact can result in serious injury, such as skin burns.
● After the device has been shut down, do not touch any hot components.
Risk of burns due to hot anti-condensation heating surface
When the temperature control limit value is reached the anti-condensation heating is switched on. Once activated, the anti-condensation heating can generate a great deal of heat. Contact can result in serious injury, such as skin burns.
● Ensure that the anti-condensation heating cannot be touched.
● Ensure that the anti-condensation heating is switched off before carrying out any repair or maintenance work.
Risk of injury at places that are difficult to access
If you do not use appropriate protective equipment when working in places that are difficult to access you are at risk of injury. For example, sharp edges and splinters can cause injuries to the head and skin. If you carry out work in the upper section using unsuitable ladders or similar, you can fall and injure yourself.
● Use appropriate protective equipment, especially a hard hat and gloves.
● Use suitable steps or ladders when working in the upper area.
Eye and skin injuries caused by deionized water
Deionized water is harmful to eyes and skin and can damage surfaces.
● Therefore, use appropriate protective clothing when you carry out any work on the drive. However, if your eyes or skin do come into contact with deionized water, rinse the affected area thoroughly with tap water as soon as possible.
● If deionized water leaks out, eliminate the source of the problem and remove the liquid from the surfaces affected.
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Safety instructions

2.6 Components that can be destroyed by electrostatic discharge (ESD)

Shutdown as a result of an incorrect residual current monitoring device
If you use a residual current monitoring device (RCD), it is possible that the residual current monitoring device will trip in error (nuisance trip). The converter may be switched off as a result of the protection device tripping in error.
● To minimize the risk of faulty trips, use a type-B RCD.

2.5 Electromagnetic fields in electrical power engineering installations

Electromagnetic fields are generated during operation of electrical power engineering installations. Electromagnetic fields can interfere with electronic devices, These devices can malfunction if electromagnetic fields are present.
Interference with pacemakers The functioning of cardiac pacemakers could be impaired by electromagnetic fields. Death or
serious physical injury can result.
● It is therefore not permissible for people with pacemakers to stand close to the device.
Data loss Electromagnetic fields can cause data loss to magnetic or electronic data storage media.
● Therefore, do not carry magnetic or electronic data storage media with you.
Persons responsible for plants and systems can find additional information on electromagnetic fields under "Information for persons responsible for plants and systems (Page 22)."
2.6 Components that can be destroyed by electrostatic discharge (ESD)
ESD guidelines
Material damage caused by electrostatic discharge. Electronic components can be destroyed in the event of improper handling, transport, storage,
and shipping.
Pack the electronic components in appropriate ESD packaging; e.g. ESD foam, ESD packaging bags and ESD transport containers.
To protect your equipment against damage, follow the instructions given below.
● Avoid physical contact with electronic components. If it is essential that you perform work on
these components, you must wear one of the following pieces of protective gear:
– Grounded ESD wrist strap
– ESD shoes or ESD shoe grounding strips if there is also an ESD floor.
● Do not place electronic components close to data terminals, monitors or televisions.
Maintain a minimum clearance to the screen (> 10 cm).
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Safety instructions

2.7 Information for nominated persons in control of an electrical installation

● Electronic components should not be brought into contact with electrically insulating materials such as plastic foil, plastic parts, insulating table supports or clothing made of synthetic fibers.
● Bring components into contact only with ESD-compliant materials, e.g. ESD tables, ESD surfaces, ESD packaging.
● Only carry out measurements on the components if one of the following conditions is met:
– The measuring device is grounded with a protective conductor, for example.
– The measuring head of a floating measuring device has been discharged directly before
the measurement.
The necessary ESD protective measures for the entire working range for electrostatically sensitive devices are illustrated once again in the following drawings. Precise instructions for ESD protective measures are specified in the standard DIN EN 61340‑5‑1.
a = Conductive floor covering c = ESD shoes or ESD shoe grounding strips e = ESD wrist strap f = Cabinet ground connection
1)
Only effective in conjunction with ESD shoes or ESD shoe grounding strips
2)
Only effective in conjunction with conductive floor covering
Figure 2-1 ESD information
1)
2)
b = ESD furniture d = ESD clothing
2.7 Information for nominated persons in control of an electrical installation

2.7.1 Proper usage

These devices are intended to be permanently installed in closed and dry rooms with a clean atmosphere. You can find the ambient and operating temperatures to be adhered to in the technical data. If the described environmental conditions are not observed, warranty claims and other claims may be rejected.
Danger to life as a result of an explosion If you operate the device in a hazardous zone, explosions can occur which can cause death,
serious injuries or material damage.
● Never operate the device in an explosive atmosphere (hazardous zone).
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SINAMICS GM150 6SL3835-2LN44-2AA0
Safety instructions
2.7 Information for nominated persons in control of an electrical installation
Danger to life when not complying with proper use of the devices Improper use of the devices described can result in death, severe injury or material damage.
● Please observe all instructions for proper use.
The nominated person in control of an electrical installation must ensure that the following points are observed:
● Follow the local and industry-specific safety and setup regulations. Observe the requirements in the guidelines specified in the "Standards and regulations" section of the "Technical data and drawings." Ensure that the specific safety and construction regulations and the regulations for using personal protective equipment are observed during all work.
● The operating instructions and the complete product documentation are always available when carrying out any work.
● The technical data as well as the specifications relating to the permissible installation, connection, ambient and operating conditions are taken into account at all times.
● Only qualified personnel or personnel supervised by responsible, skilled specialists are allowed to carry out basic planning and all work on the device.
● During shipping, specific transport conditions are adhered to.
● Assembly is performed according to assembly instructions. Separate cabinet units are connected properly (cables and busbars).
● All instructions for EMC-compatible installation, cabling, shielding, grounding, and for adequate auxiliary power supply are to be observed.
● Commissioning is only to be performed by qualified personnel trained for that purpose in accordance with the commissioning instructions.
● System configuration is carried out by an experienced system integrator. Additional system components - such as circuit-breaker, transformer, cables and motor - are coordinated and harmonized with one another for drive operation.
● The device is only operated in conjunction with the engineered components.
● Different operating modes, overloads, load cycles, and differing environmental conditions are permitted only after special arrangement with the manufacturer.
Make use of the support and services offered by the relevant service center for planning, installation, commissioning, and servicing work. You can find the relevant contact person under "Service & Support (Page 219)".
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Safety instructions
2.7 Information for nominated persons in control of an electrical installation

2.7.2 Grounding concept

Draw-up a grounding concept and integrate the device into this concept. The grounding concept must take into consideration national provisions and system specifics. Ensure that the following criteria are fulfilled:
● At the installation site, the various subunits must be screwed together to establish a good electrical connection between them.
● If shield busbars are provided, these must be connected together.
● The protective grounding conductor must be connected to the system the grounding point. Select the highest cross-section of the protective grounding conductor from one of the following variants:
– According to local wiring regulations
– Calculated according to IEC 60364-5-54, 543.1
– Half a phase conductor cross-section

2.7.3 Installation site safety

Danger due to an unsecured installation location
This device is used in industrial power installations. Improper use, incorrect operation, insufficient maintenance, and access by unauthorized persons can lead to accidents. The results can be death, serious bodily injury or damage to property.
● Install the device in electrical rooms where only qualified personnel have access. If this is not possible, then ensure that a barrier prevents uncontrolled access. Use safety fences and appropriate signs, for example, to prevent unauthorized entry to the zone that has been fenced off.
● Place notices that indicate that only trained personnel are allowed to operate and carry out maintenance and repair work.
● To comply with safety regulations, equip plants and systems with additional monitoring and protective devices. Follow technical equipment legislation and accident prevention regulations.
Note
The converter will be supplied on request without an electromechanical door interlocking system if space is restricted. In this instance, the customer must provide an access interlock system compliant with IEC 61800-5 /-1.
Note
The drive does not have a grounding breaker at the input/output. The system operator must, therefore, ensure that there is sufficient grounding.
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2.7.4 Measures for operator protection in electromagnetic fields

The plant operator is responsible for taking the following appropriate measures (labels and hazard warnings) to adequately protect operating personnel against any possible risk.
● Observe the relevant nationally applicable health and safety regulations or the applicable
national regulations in the country of installation. In Germany, "electromagnetic fields" are subject to regulations BGV B11 and BGR B11 stipulated by the German statutory industrial accident insurance institution.
● Display adequate hazard warning notices on the installation.
● Place barriers around hazardous areas.
● Take measures, e.g. using shields, to reduce electromagnetic fields at their source.
● Make sure that personnel are wearing the appropriate protective gear.
Safety instructions

2.8 Residual risks

2.8 Residual risks
According to the EU machinery directive, machine manufacturers / plant operators must conduct a risk assessment of their machine. Plant operators must conduct a risk assessment of their plant. In particular, pay attention to Annex 1 "General Principles" of the EU machinery directive.
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Safety instructions
2.8 Residual risks
Pay attention to the following residual risks:
● Unintentional movements of driven machine parts Unintentional movements of driven machine parts can occur during commissioning, operation, maintenance, and repair, e.g. from the following causes:
– Hardware defects and/or software errors in the sensors, controllers, actuators, and
connection technology
– Response times of the controller and drive
– Operating and/or environmental conditions outside of the specification
– Condensation/conductive contamination
– Parameterization, programming, cabling, and installation errors
– Use of radio devices/cell phones in the immediate vicinity of the controller
– External influences/damage
● High temperatures and emissions A fault can occur as a result of the following, for example:
– Component malfunctions
– Software errors
– Operating and/or environmental conditions outside of the specification
– External influences/damage
For instance, a fault can have the following effects:
– Extraordinarily high temperatures, including open fires as a result of the fault
– Emissions of light, noise, particles or gases
Devices with "Open Type/IP20 degree of protection" must be installed in an electrical room or a comparable environment.
● Hazardous shock voltages Hazardous shock voltages can result from the following causes, for example:
– Component malfunctions
– Induction of voltages in moving motors
– Operating and/or environmental conditions outside of the specification
– Condensation/conductive contamination
– External influences/damage
● The release of substances and emissions that are harmful to the environment Improper operation or the improper disposal of components can harm the environment.
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Safety instructions

2.9 Security information

● Damage from pressure build-up during electric arcs in the event of a fault
If the building has not been designed correctly in terms of how it has been dimensioned, damage can result from the pressure that can possibly build up inside.
● Dangerous electric arcs during internal faults
The devices have been designed according to the relevant IEC standards, and tested in line with strict type-testing procedures. They were developed and manufactured so that there is a very low probability of internal faults occurring. However, internal faults cannot be completely ruled out.
WARNING
Dangerous electric arcs during internal faults
Defects such as damage to components, overvoltages, or loose parts, as well as exceptional operating statuses, can cause a failure within the enclosure. This can result in an internal electric arc. If an electric arc occurs and people are nearby, this could lead to death, serious physical injury, and damage to property.
● Ensure that only qualified personnel perform any work that is required.
● Observe the safety and operating instructions in this documentation and labels attached to the device for any work that is performed.
2.9 Security information
Siemens provides products and solutions with industrial security functions that support the secure operation of plants, systems, machines and networks.
In order to protect plants, systems, machines and networks against cyber threats, it is necessary to implement – and continuously maintain – a holistic, state-of-the-art industrial security concept. Siemens’ products and solutions constitute one element of such a concept.
Customers are responsible for preventing unauthorized access to their plants, systems, machines and networks. Such systems, machines and components should only be connected to an enterprise network or the internet if and to the extent such a connection is necessary and only when appropriate security measures (e.g. firewalls and/or network segmentation) are in place.
For additional information on industrial security measures that may be implemented, please visit https://www.siemens.com/industrialsecurity (
Siemens’ products and solutions undergo continuous development to make them more secure. Siemens strongly recommends that product updates are applied as soon as they are available and that the latest product versions are used. Use of product versions that are no longer supported, and failure to apply the latest updates may increase customer’s exposure to cyber threats.
To stay informed about product updates, subscribe to the Siemens Industrial Security RSS Feed under https://www.siemens.com/industrialsecurity (https://www.siemens.com/industrialsecurity).
https://www.siemens.com/industrialsecurity).
Additional notes for this product are provided in the Internet.
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Safety instructions
2.9 Security information
"SINAMICS Industrial Security" Manual
Notes relating to Industrial Security are provided here (
support.industry.siemens.com/cs/ww/de/view/109751848/en).
"Security Guidelines for SIMATIC HMI devices" Manual
Notes relating to Industrial Security for HMI devices are available here. (https://
support.industry.siemens.com/cs/de/en/view/109481300)
https://
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Description

3.1 Applications

The drive is a medium-voltage drive for phase-rotation-controlled machines. The drive is a single drive designed for applications with a quadratic, constant load characteristic and no regenerative feedback. Typical applications include pumps, fans, compressors, extruders, mixers, and mills.

3.2 Safety concept

The device and its associated components are subject to an extensive safety concept. When used properly, the security concept guarantees safe installation, safe operation as well as safe service and maintenance.
The safety concept encompasses safety components and functions to protect the device and operators. The device is also equipped with monitoring functions to protect external components.
3
The device operates safely when the interlock and protection systems are functioning properly. Nevertheless, there are areas that are hazardous for personnel and that cause material damage if the safety information of all the instructions and the labels on the device are not strictly complied with.

3.2.1 Safety components and functions

The following safety components and functions are installed to protect personnel:
● The make-proof grounding switch for grounding the voltage DC link.
● The electromechanical door interlocking system prevents access to the power unit while operational. The doors cannot be opened until the grounding switch has been closed. The door for the control section, however, can be opened for monitoring purposes even during operation.
● The electromechanical interlock system for the make-proof grounding switch prevents the make-proof grounding switch from closing for the voltage DC link. The make-proof grounding switch can only be closed if the circuit-breaker is open and the DC link has been completely discharged.
● The EMERGENCY OFF mushroom pushbutton in the cabinet door is a pushbutton with mechanical interlock system for EMERGENCY OFF, Stop Category 0 (standard).
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Description
3.2 Safety concept
Note
As option, the make-proof grounding switch also serves to ground the input side (option L48) and the output side (option L49).

3.2.2 External safety components

The following external components for the safety concept are provided:
● Circuit breaker More detailed information is provided in Chapter Circuit-breaker (provided by the customer) (Page 38).
● Input-side transformer The transformer on the input side must be configured in such a way that the maximum short­circuit current is not exceeded. Information on this is provided in the technical data sheet of the transformer.

3.2.3 Protection and monitoring functions of internal components

The internal components of the drive have the following protection and monitoring functions:
● Crowbar
● Device protection using monitoring systems:
– Current monitoring
– DC-link monitoring
– Output voltage monitoring
– Thermal monitoring of the power unit
– Precharge monitoring
– Insulation monitoring
– Supply voltage monitoring
– GSV monitoring
– Circuit-breaker monitoring
– Re-cooling unit monitoring
● Shutdown in the event of semiconductor failure
● Shutdown in the event of control component failure
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