Siemens SIROTEC, SIMODRIVE, SIMOTION, SINAMICS S120, SINUMERIK Planning Manual

Planning Guide 03/2004 Edition

EMC Installation Guideline SINUMERIK, SIROTEC, SIMODRIVE SIMOTION, SINAMICS S120

Introduction

EMC Basic Rules

Interference Spreading

Equipotential Bonding

Control Cabinet

Structure

Wiring and Shielding

Filtration

Troubleshooting and

Fault Elimination

Electrostatically

Sensitive Assemblies

(ESA)

EMC Law and CE

Mark

Health Protection

Index

EMC Installation Guideline

Planning Guide

Valid for

SINUMERIK SIROTEC SIMODRIVE SIMOTION SINAMICS S120

03.2004 Edition

Identification of the documentation

This book is part of the documentation on CD-ROM (DOCONCD)

Edition Order No. Remarks

03.04 6FC5298-7CA00-0BG0

Trademarks SIMATIC®, SIMATIC HMI®, SIMATIC NET®, SIROTEC®, SINUMERIK® and SIMODRIVE® are registered trademarks of Siemens AG. IBM® is a registered trademark of International Business Corporation. MS-DOS® and WINDOWS

are registered trademarks of Microsoft Corporation. Other product names used in this

documentation may be trademarks which, if used by third parties, could infringe the rights of their owners.

Printing history

Brief details of this edition and previous editions are listed below.

The status of each edition is shown by the code in the "Remarks" columns.

Status code in the "Remarks" column:

A .... New documentation.

B .... Unrevised reprint with new order no.

C .... Revised edition with new status.

Edition Order No. Remarks

12.98 6FC5297-0AD30-0BP0

06.99 6FC5297-0AD30-0BP1

03.04 6FC5297-0AD30-0BP2

Further information is available on the Internet under: http://www.siemens.com/motioncontrol

This publicatio was produced with WinW ord V 8.0 and Designer V 7.0 and the DocuTool AutWinDoc.

The reproduction, transmission, or use of this document or its contents is not permitted without express written authority. Offenders will be liable for damages. All rights, including those created by patent grant or registration or a utility model or design, are reserved.

We have checked that the contents of this document corresponds to the hardware and software described. Nonetheless, differences might exist and therefore we cannot guarantee that they are completely identical. The information contained in this documentation is, however, reviewed regularly and any necessary changes will be included in the next edition. We welcome suggestions for improvement.

Subject to change without prior notice

Order No. 6FC5297-0AD30-0BP2 Printed in Germany

Siemens Aktiengesellschaft

Preface

What does EMC mean

EMC is the abbreviation for electromagnetic compatibility. Electromagnetic compatibility is defined as the characteristic of a piece of electrical equipment to function satisfactory in a predetermined electromagnetic environment without influencing this environment unduly.

Who is this manual for

· Project managers creating NC and drive system configurations.

· Installers routing the connection lines.

· Service engineers involved in troubleshooting and fault elimination.

Machine manufacturers

The notes indicated in Chapters 2, 4, 5, 6, 7, 9, 10, 11 are primarily directed towards machine manufacturers, who can influence or change the functional behaviour of the complete system by means of the described measures.

Subject matter of this manual

You receive the following information in this Guideline:

· Why are EMC guidelines necessary?

· Which interference sizes have an effect on the control from outside

(interference sink)?

· How can EMC malfunctions be prevented?

· Which practical application examples are available for a trouble-free system

structure?

· What must be considered when handling electrostatically sensitive assemblies?

· How can a malfunction caused by a deficient EMC be eliminated?

Objectives

These guidelines are not, and do not aim to be, a textbook for EMC. The purpose of these guidelines is to provide the practical person with instructions for securing the EMC.

Compliance with these EMC guidelines are necessary to a) achieve a minimum noise immunity of the accessories in such a way that they

function perfectly in a harsh industrial environment and

b) to not have an undue impact on the environment in terms of radio interference.

Preface

vi EMC Installation Guideline – Planning Guide (EMV) – 03.2004 Edition

These guidelines also describe the necessary measures according to the European Union (EU) directives for compliance with the EMC law or the EMC guidelines.

In installation locations with extremely high interference levels, malfunctions can be caused despite compliance with these EMC Guidelines, although it is very unlikely.

What prior knowledge is required?

Apart from these EMC Guidelines, international and country-specific safety regulations continue to apply.

Good knowledge of the relevant standards and EU regulations is necessary, so that the safety concerns are not impaired when implementing these EMC Guidelines. The implementation of these EMC Guidelines must be performed by qualified personnel.

Qualified personnel

All persons who are entrusted with the installation, assembly, commissioning and operation of the product and who possess the necessary qualifications are to be considered to be qualified personnel.

The authorization to connect circuits and devices in accordance with the approved standards of electrical engineering, to bring them into operation and to remove them from operation applies as a particular qualification.

Hotline

If you have any questions, please get in touch via our hotline:

A&D Technical Support Phone.: ++49-(0)180-5050-222 Fax: ++49-(0)180-5050-223 Email: adsupport@siemens.com

If you have any questions about the documentation (suggestions, corrections, etc.), please send a fax or e-mail to: Fax: ++49-(0)9131-98-2176 Email: motioncontrol.docu@erlf.siemens.de

Fax form: See the reply form at the end of the document.

Internet addresses

Motion Control Systems: http://www.siemens.com/motioncontrol

Finding your way around

To assist you in your orientation, you have a table of contents and an index.

Preface

vii

Safety and warning concept

The following safety and warning information is used in this document. Explanation of symbols used:

Danger

Indicates an imminently hazardous situation which, if not avoided, will

result in

death or serious injury or in substantial property damage.

Warning

Indicates a potentially hazardous situation which, if not avoided, could

result in

death or serious injury or in substantial property damage.

Caution

This symbol (with a warning triangle) indicates that minor injury or damage to property may

result if proper precautions are not taken.

Caution

Used without safety alert symbol indicates a potentially hazardous situation which, if not avoided, may

result in property damage.

Notice

Used without the safety alert symbol indicates a potential situation which, if not avoided, may

result in an undesirable result or state.

Preface

viii EMC Installation Guideline – Planning Guide (EMV) – 03.2004 Edition

Other information

Important

Important indicates an important or especially relevant item of information.

Note

Note refers to an important item of information about the product, handling of the product or part of the documentation which is particularly relevant in the current context.

Machine manufacturer

This symbol appears in this documentation whenever the machine manufacturer can influence or modify the described functional behavior. Please observe the information provided by the machine manufacturer!

Contents

1 Introduction ..................................................................................... 1-11

2 EMC Basic Rules............................................................................. 2-13

3 Interference Spreading................................................................... 3-15

3.1 Interference sources ..................................................................... 3-16

3.2 Interference sinks.......................................................................... 3-16

3.3 Coupling paths .............................................................................. 3-17

4 Equipotential Bonding.................................................................... 4-19

4.1 Equipotential bonding in built-in cabinets...................................... 4-20

4.2 Equipotential bonding of external components ............................. 4-22

4.3 Examples of equipotential bonding ............................................... 4-25

5 Control Cabinet Structure .............................................................. 5-29

5.1 Design and assembly of the cabinet ............................................. 5-29

5.1.1 Earthing of control cabinet components .................................... 5-29

5.1.2 Breakdowns in the control cabinet wall...................................... 5-29

5.2 Assembly of the components in the control cabinet...................... 5-31

5.3 Wiring, shielding and earthing....................................................... 5-33

6 Wiring and Shielding ...................................................................... 6-35

6.1 Cable running................................................................................ 6-35

6.2 Shielding ....................................................................................... 6-37

6.2.1 Introduction ................................................................................ 6-37

6.2.2 Basic rules for the shield connection of simple shielded lines... 6-38

6.2.3 Shielding measures with power lines......................................... 6-40

6.2.4 Further conduction of the line shield at the interruption point .... 6-41

6.2.5 Example of shield connections .................................................. 6-42

7 Filtration........................................................................................... 7-45

7.1 Interference suppression of inductors........................................... 7-45

7.2 Filter .............................................................................................. 7-46

8 Troubleshooting and Fault Elimination ........................................ 8-49

8.1 Troubleshooting ............................................................................ 8-49

8.2 Fault clearance.............................................................................. 8-49

Contents

x EMC Installation Guideline – Planning Guide (EMV) – 03.2004 Edition

9 Electrostatically Sensitive Assemblies (ESA) .............................. 9-51

9.1 What does ESD mean? ................................................................ 9-51

9.2 Electrostatic charging of objects and people ................................ 9-52

9.3 Packing and dispatch of electrostatically sensitive assemblies .... 9-52

9.4 Basic protective measures against static electricity discharges ... 9-53

10 EMC Law and CE Mark ................................................................. 10-55

10.1 Notes on the EMC rule................................................................ 10-55

10.2 Notes for machine manufacturers............................................... 10-56

10.3 CE mark/EU declaration of conformity........................................ 10-56

11 Health Protection .......................................................................... 11-59

I Index.................................................................................................. I-61

1-11

1 Introduction

To attain the electromagnetic compatibility (EMC) requested in the EMC Guideline of a complete plant (control and drive engine), EMC measures on the part of the control manufacturer and user (including machine tool manufacturer) are required.

Concerning manufacturer

EMC compatible design (electrically and mechanically)

Concerning

user

EMC compatible installation (in the room with cabling)

EMC compatible total system

Fig. 1-1 Securing the EMC

Important

To secure the EMC, you must pay attention to the:

· product-specific EMC measures contained in the EMC Guidelines,

· to project or operate only permitted combinations and

· to use the accessories provided in the product-specific documentation

(e.g. ready-made wiring) or equivalent.

Introduction

1-12 EMC Installation Guideline – Planning Guide (EMV) – 03.2004 Edition

Notes

2-13

2 EMC Basic Rules

Mass of metal parts

· Connect all metal parts of the control cabinet flat and well-conducting with each other.

· Connect the cabinet doors via short ground straps (upper, middle, lower) with the cabinet beam.

· Connect the shield bus and potential compensation bus extensively with the cabinet housing.

· Create permanent connections of the metal parts. Perform screw connections on painted and anodized metal parts either by means of special contact discs or permanently remove the insulating protective layer between the parts.

· Do not use any aluminium parts if possible (danger of oxidation).

Filter

· Filter must usually be mounted directly at the place where the line to be filtered enters the cabinet.

· Specific filters such as e.g. the SIMODRIVE filter module or the STEPDRIVE filter must be placed, mounted and connected according to the manufacturers’ documentation.

· Filters must be fastened in such a way that they lie flat and have a good, durable, conductive connection to the cabinet housing (assembly plate).

· The lines running to the filters must be separated from the lines exiting the filters. Filtered lines must be run separately from unfiltered lines.

Cable running

· Route the signal-/data lines spatially separated from the power current-/power supply lines (avoid coupling routes). Minimum distance in the control cabinet: 20 cm. Use an earthed separating plate, if necessary.

· Twist unshielded lines of the same circuit (forward and return conductor) if possible or minimize the distance between the forward and return conductor.

· Route the lines as close as possible to metallic housing parts (e.g. assembly plate, supporting beams, metal rails).

· Route signal lines and the appropriate potential compensation line as close as possible to each another.

· Never route signal lines on devices which produce strong magnetic fields. (e.g. motors, transformers).

· If possible, insert the signal/data lines at only one level (e.g. only from below) into the cabinet.

EMC Basic Rules

2-14 EMC Installation Guideline – Planning Guide (EMV) – 03.2004 Edition

· Avoid unnecessary line lengths (also with spare lines).

· Signal lines in particular nominal and actual value lines should be routed

without breaks. Ensure continuous shielding at the dividing points.

Fastening the line shields

· Earth the shields of the data lines, analog signal lines and power lines on both sides extensively and well conducting.

· Line shields should be inserted directly after the entry of the line into the cabinet onto a shield bus and routed up to the component. The shield contact is ensured by screwing the plug to the component housing via the productspecific, ready-made lines.

· Only metallic or metallized plug housings must be used for shielded lines.

Remedy of possible interference sources

· The coils of contactors, relays, solenoid valves and other inductors in the cabinet, also perhaps in adjacent environment must be wired. Wiring is performed, for example with RC elements, varistors, etc., directly on the respective coil.

· Use light bulbs as possible for the lighting of cabinets. Avoid the use of fluorescent lamps.

Uniform system reference potential

· If system components are housed in different cabinets, then they must be connected via e.g. an equipotential bonding conductor.

· Adequately-sized equipotential bonding lines must be used against potential differences between system parts.

Measures against the effects of lightning strikes

Measures must be taken in buildings, rooms and electrical devices for the protection of the electrical appliances against overvoltage, caused by lightning strikes. Therefore we recommend you to contact your Siemens office or the relevant specialist firms.

Handling of components susceptible to electrostatic damage

· Wear an electrostatic wristband when working with components susceptible to suffering damage due to electrostatic discharge.

· Use storage surfaces suitable for electrostatically damageable components and packaging made of electrostatically safe materials, e.g. uncoated cardboard boxes.

· See also Chapter 9.

3-15

3 Interference Spreading

Electromagnetic interference sizes have only an effect on a control or system when the following three components are available:

• Interference source

• Coupling path

• Interference sink

Source of interference

(interfering object)

Potentially susceptible equipment

(interfered device)

e.g. drive unit, motor, inductivity

Data link

e.g. setpoint cabel

e.g. positioning control, numerical control

Fig. 3-1 Electromagnetic environment

Interference Spreading

3-16 EMC Installation Guideline – Planning Guide (EMV) – 03.2004 Edition

3.1 Interference sources

The initiator of the interference is described as the interference source. The noise levels generated by the interference sources or their effects must be eliminated or at least dampened by appropriate measures.

Table 3-1 Typical interference sources and their effects on interference sinks

Interference source

Interference generated

by…

Effect

Switched inductors such as e.g. contactors, relays, electronic valves

- Contacts

- Coils

- System disturbances

- Electromagnetic fields

- Magnetic fields

Electrical motors - Collectors

- Coils

- Electromagnetic fields

- Magnetic fields Sparking machines such as e. g. electrical welding equipment, electrical discharge machines

- Contacts

- Transformers

- Electromagnetic fields

- System disturbances

- Compensating currents

- Magnetic fields Power supply units - Circuits

- Switching components

- Electromagnetic fields

- System disturbances High-frequency appliances - Circuits - Electromagnetic fields Transmitters - Antennas - Electromagnetic fields Earth or reference potential differences

- Voltage differences - Compensating currents

Operator - Discharges of static

electricity

- Electrical discharge currents

- Electrical fields Power lines - Current flows

- Fuse cases

- Power break-ins, power

overvoltages

- Electrical and magnetic fields Transmission lines - Voltage differences

- Corona discharges

- Electromagnetic fields

- Electrical fields Current converters, power electronics - Circuits - Overvoltages

- Compensating currents

3.2 Interference sinks

An interference sink is an electrical device, whose function can be influenced by interference sizes.

Table 3-2 Typical interference sinks and their reaction on interferences

Interference sinks are sensitive against… Reaction

Microprocessor-controlled systems, bus systems

Pulse-shaped noise levels (e.g. switching operations) and electromagnetic fields

Sporadic processor shutdown, transmission errors

Analog circuits Low-frequency noise levels (e.g.

potential differences)

Superimposition of the effective signal on the noise level (e.g. 50 Hz hum on setpoint)

Electron beam monitors low-frequency magnetic fields

(> 1.5 A/m)

Flickering screen or image, colour

distortion Telephones Mains second harmonics Whistling is audible Fax machines, power supply units

Mains second harmonics Fuse case or defect in the power supply

unit, whistling is audible

Interference Spreading

3-17

3.3 Coupling paths

The coupling path is the transmission path for the noise levels generated by an interference source. Through them, the noise levels can spread from the interference source to the interference sink. Different coupling mechanisms exist for the interference coupling:

Table 3-3 Coupling mechanisms and their typical interference sources

Coupling mechanism Interference sources

Galvanic coupling

Interferenc e source

Conductive coupling path

Interference sinks

Galvanic or metallic coupling always occurs when two circuits jointly use a conductor (e.g. joint earth line).

• Cycled appliances (mains

influence by converter and external power supply units)

• Starting motors

• Different potential of component

housings with common power supply

Capacitive coupling

Interference

source

Capacitive

coupling path

Interference sink

Capacitive or electrical coupling occurs between mutually insulated conductors which are on a different potential.

• Interference coupling by parallel

running line

• Static discharge of the operator

• Contactors

Inductive coupling

Interference

Inductive

coupling

path Interference sink

Useful signal

source

Inductive or magnetic coupling occurs between conductor loops of those at least one is live. The magnetic flows linked with the currents induce interference voltages.

• Transformers, motors, electrical

welding equipment

• Parallel running power line

• Lines with switched currents

• Signal line with high frequency

• Non-switched solenoids

Radiation coupling

Interference source

Radiated coupling path

Interference

sink

Radiation coupling is present if an electromagnetic wave hits a line formation. The hit of the electromagnetic wave induces currents and voltages.

• Adjacent transmitter (e.g. walkie-

talkies)

• Spark paths (spark plugs,

collectors of electric motors, welding equipment)

Interference Spreading

3-18 EMC Installation Guideline – Planning Guide (EMV) – 03.2004 Edition

Table 3-4 Examples for coupling paths

Coupling path Cause

Lines

• Incorrect or inappropriate laying

• Missing or incorrectly connected shield

• Inappropriate spatial arrangement of the lines (incl. equipotential

bonding line)

• Unsuitable lines

Control cabinet or housing of the controls

• Missing or incorrectly wired compensation line

• Missing or incorrect earthing

• Inappropriate spatial arrangement

• Components not mounted securely

• Unfavourable cabinet structure

4-19

4 Equipotential Bonding

Note

Equipotential bonding must not be confused with protection against electric shock by means of a protective line system. This protective measure must be performed according to the appropriate standards and guidelines and is not a constituent part of these EMC Guidelines.

Why is equipotential bonding necessary?

Basic principle:

Control components between which a signal connection exists also require a potential connection. System malfunctions of the electrical components are prevented by equipotential bonding between the electrical components among each other and the earth.

Where is equipotential bonding required?

a) Between all control components which are also interconnected to each other

via signals.

b) Between control components and the central earthing bar.

Note

The central earthing bar is a bus bar for all earth, equipotential bonding and protective conductors of a control cabinet. The external protective conductor or the building earthing system is also connected to this bus.

Exception:

A potential connection is not necessary for control components with potential-free signal transmission (e. g. via light wave conductor), in many cases it is also not permissible.

No direct potential connection line is required (applicable to all digital signal transmissions between the central appliance and the cabinet external components) for control components, for which the signal transmission is conditionally potentialfree, i.e. it is only potential-free up to a certain voltage level. Here a short potential connection to the respective earth (reference potential) is sufficient.

Equipotential Bonding

4-20 EMC Installation Guideline – Planning Guide (EMV) – 03.2004 Edition

4.1 Equipotential bonding in built-in cabinets

Equipotential bonding via meshing

The equipotential bonding between the individual control components among each other and the central earthing bar within a metallic housing (cabinet) should preferably be performed by meshing.

Meshing is understood to mean the conducting connection of several components, whereby a direct conducting connection exists between all components. (See Section 4.2, Fig. 4-1).

Points to bear in mind:

• Components with metal housings must be bolted onto the cabinet housing

(assembly plate). Ensure an large-surface conducting connection.

Note

This direct galvanized connection of the metal housing to the cabinet rear via the component fastening bolts is only possible if the terminal at the control

components (designation:

or ) for the equipotential bonding line has a large-surface galvanic connection with the fastening bearing surface of the components.

In the event that the control components have an insulated housing fastening or the fastening facing consists of metallized (galvanized) plastics, the connection between the equipotential bonding terminal of the component and the cabinet

housing must be provided ≥ via a short equipotential bonding line 10 mm

(see Section 4.2 Fig. 4-1, component 3).

• The connection between the central earthing bar and the cabinet housing must

be low-resistance, short and with a large surface area.

• All contact surfaces for earth connections must be metallically bare. It is

absolutely essential to remove the oxide and colour coat permanently.

• The corrosion resistance of the earth connections must be ensured, particularly

in respect of contact corrosion and resistance against external influences.

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