Medium-Voltage Drive - Siemens

www.siemens.com/drives

Medium-Voltage Drive

SINAMICS GL150Type 6SL38503UN116AA0Z

Operating InstructionsInstallation Instructions

Edition 10/2019

This documentation pertains toEXAMPLE

28.10.2019 14:16V18.00

Medium-Voltage Drive

SINAMICS GL150Type 6SL38503UN116AA0Z

Operating InstructionsInstallation Instructions

This documentation pertains toEXAMPLE

Edition 10/2019

Introduction 1

Safety information 2

Description 3

Preparations for use 4

Mounting 5

Electrical connection 6

Commissioning 7

Operation 8

Maintenance 9

Spare parts 10

Disposal 11

Service & Support ATechnical specifications and drawings B

Legal informationWarning 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.

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

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

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

NOTICEindicates 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 PersonnelThe 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 productsNote the following:

WARNINGSiemens 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.

TrademarksAll 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 LiabilityWe 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 AGLarge Drives ApplicationsVogelweiherstr. 1-1590441 NÜRNBERGGERMANY

Document order number: 0009938503-000030Ⓟ 10/2019 Subject to change

Copyright © Siemens AG 2019.All rights reserved

Table of contents

1 Introduction.................................................................................................................................................13

1.1 About these Operating Instructions........................................................................................13

1.2 Text format features ...............................................................................................................13

2 Safety information.......................................................................................................................................15

2.1 Warning symbol on the device ...............................................................................................15

2.2 Qualified personnel ................................................................................................................15

2.3 The 5 safety rules...................................................................................................................15

2.4 Safe handling .........................................................................................................................16

2.5 Electromagnetic fields in electrical power engineering installations ......................................18

2.6 Components that can be destroyed by electrostatic discharge (ESD)...................................19

2.7 Information for nominated persons in control of an electrical installation...............................202.7.1 Proper usage..........................................................................................................................202.7.2 Grounding concept.................................................................................................................222.7.3 Installation site safety.............................................................................................................222.7.4 Instructions for inverters with no grounding switch ................................................................232.7.5 Measures for operator protection in electromagnetic fields ...................................................232.7.6 Operator protection measures for demagnetization equipment .............................................23

2.8 Residual risks.........................................................................................................................24

2.9 Security information ...............................................................................................................25

3 Description..................................................................................................................................................27

3.1 Area of application .................................................................................................................27

3.2 Safety concept .......................................................................................................................273.2.1 Safety components and functions ..........................................................................................283.2.2 Safety information for IEC 61800-5........................................................................................283.2.3 External safety components...................................................................................................293.2.4 Protection and monitoring functions of internal components .................................................293.2.5 Protection and monitoring functions for external components ...............................................29

3.3 Power unit ..............................................................................................................................303.3.1 Product features.....................................................................................................................303.3.2 Power unit components..........................................................................................................313.3.2.1 Design of the thyristor stack...................................................................................................313.3.2.2 Design of the thyristor modules..............................................................................................333.3.2.3 DC-link reactor .......................................................................................................................333.3.2.4 AVT combination module .......................................................................................................333.3.2.5 Power Stack Adapter .............................................................................................................343.3.2.6 Current transformer................................................................................................................343.3.2.7 Fans .......................................................................................................................................353.3.2.8 Differential-pressure switch....................................................................................................35

SINAMICS GL150 6SL38503UN116AA0ZOperating Instructions Rev.201910281416 EXAMPLE 5

3.3.2.9 Surge arresters ......................................................................................................................353.3.2.10 Door limit switches .................................................................................................................353.3.3 Principle of operation .............................................................................................................353.3.3.1 Fuseless technology ..............................................................................................................353.3.3.2 Thyristor electronics ...............................................................................................................373.3.3.3 Voltage actual value sensing .................................................................................................383.3.3.4 Ground fault detection............................................................................................................39

3.4 Closed-loop control ................................................................................................................413.4.1 Structure.................................................................................................................................413.4.2 Indicator lights ........................................................................................................................413.4.3 Key-operated switch...............................................................................................................413.4.4 Fan in the door .......................................................................................................................413.4.5 Mushroom pushbutton ...........................................................................................................413.4.6 Operator panel AOP30...........................................................................................................423.4.7 Description of the components...............................................................................................443.4.7.1 SINAMICS Control Unit ..........................................................................................................443.4.7.2 DRIVE-CLiQ interface ............................................................................................................443.4.7.3 Terminal Modules...................................................................................................................443.4.7.4 Voltage Sensing Module ........................................................................................................453.4.7.5 DC/DC converter....................................................................................................................453.4.7.6 SITOP Select .........................................................................................................................453.4.7.7 Sirius safety relay...................................................................................................................45

3.5 Options...................................................................................................................................453.5.1 Triggering additional circuit breakers (option A04).................................................................453.5.2 Expanded remote control via terminal block (option A06)......................................................463.5.3 Motor monitoring (option A09)................................................................................................463.5.4 Internal synchronizing voltage detection (option A11) ...........................................................463.5.5 Integrated SIMATIC S7 controller with basic level of equipment ...........................................463.5.6 Fans in the closed-loop control cabinet (option A20) .............................................................463.5.7 Anti-condensation heating for the closed-loop control (A21) .................................................473.5.8 Speed sensing for four motors (only starting converters) (option A54)..................................473.5.9 Dry transformer monitoring (option A72)................................................................................473.5.10 Oil transformer monitoring (option A73) .................................................................................473.5.11 Extended dry transformer monitoring (option A74) ................................................................473.5.12 Extended oil transformer monitoring (option A75)..................................................................483.5.13 Starting converter for four motors (interfaces for parallel switching device and static

excitation equipment) (option A94) ........................................................................................483.5.14 PROFINET interface (option G24) .........................................................................................483.5.15 DeviceNet interface (option G23)...........................................................................................483.5.16 Optical link module (option G74)............................................................................................483.5.17 Diagnostics module PADU8-M (option G76)..........................................................................493.5.18 Electronic power supply with wide-range power supply unit 1 AC 93 - 253 V, or DC 88 -

360 V (option K71) .................................................................................................................493.5.19 Inductive cable attenuation (option L05) ................................................................................493.5.20 Demagnetization device for output transformer for starting converters (option L30) .............493.5.21 Cabinet lighting in the control section (option L50) ................................................................523.5.22 Cabinet anti-condensation heating for the power unit (option L55)........................................523.5.23 Dust protection (option M11)..................................................................................................523.5.24 Brass cable entry for power and signal cables (option M36) .................................................523.5.25 Degree of protection IP41 (option M41) .................................................................................523.5.26 Low-noise fan (option M65)....................................................................................................52

Table of contents

SINAMICS GL150 6SL38503UN116AA0Z6 Operating Instructions Rev.201910281416 EXAMPLE

4 Preparations for use ...................................................................................................................................53

4.1 Notes for system integrators ..................................................................................................534.1.1 Requirements for transformers ..............................................................................................534.1.2 Selection and configuration of multi-winding transformers.....................................................544.1.3 Requirements for the circuit breaker provided by the customer.............................................554.1.4 Requirements for cables ........................................................................................................58

4.2 Requirements when mounting and installing the device ........................................................594.2.1 Requirements for installation location ....................................................................................594.2.2 Requirements placed on the levelness of the floor ................................................................60

4.3 Inspections when receiving the delivery.................................................................................604.3.1 Checking shock and tilt indicators..........................................................................................604.3.2 Checking the load handling attachments ...............................................................................61

4.4 Transportation ........................................................................................................................624.4.1 Transport markings ................................................................................................................624.4.2 Transport requirements..........................................................................................................624.4.3 Observe center of gravity .......................................................................................................634.4.4 Transport with a fork-lift truck.................................................................................................634.4.5 Transport with a crane ...........................................................................................................644.4.6 Using lifting rods.....................................................................................................................644.4.7 Transporting transportation units packed in boxes ................................................................66

4.5 Unpacking ..............................................................................................................................674.5.1 Removing the packaging........................................................................................................674.5.2 Removing load securing devices ...........................................................................................684.5.3 Lifting the cabinet off the transport pallet ...............................................................................684.5.4 Opening doors in preparation for use.....................................................................................694.5.5 Checking the shock and tilt indicators inside the cabinet.......................................................69

4.6 Storage...................................................................................................................................704.6.1 Storing a device .....................................................................................................................704.6.2 Storing fans ............................................................................................................................71

5 Mounting.....................................................................................................................................................73

5.1 Safety instructions for installation...........................................................................................73

5.2 Tools required ........................................................................................................................74

5.3 Torques ..................................................................................................................................74

5.4 Screwing the transport units together ....................................................................................75

5.5 Connect to the foundation ......................................................................................................76

5.6 Mounting fans.........................................................................................................................76

5.7 Ensuring cooling air................................................................................................................77

6 Electrical connection...................................................................................................................................79

6.1 Safety instructions for electrical connection ...........................................................................79

6.2 Note on shielded cables.........................................................................................................81

6.3 Electromagnetic compatibility.................................................................................................81

6.4 Potential concept....................................................................................................................84

Table of contents


6.5 Connecting equipotential-bonding conductors .......................................................................84

6.6 Using the equipotential bonding strip and shield bus.............................................................85

6.7 Connecting the protective grounding .....................................................................................85

6.8 Laying the signal lines............................................................................................................86

6.9 Laying the cable shields.........................................................................................................86

6.10 Separating adjacent cabinets using unsuppressed contactors ..............................................86

6.11 Laying additional wiring..........................................................................................................87

6.12 Connecting the power unit .....................................................................................................876.12.1 Connecting power cables.......................................................................................................876.12.2 Connecting the signal cables .................................................................................................89

6.13 Connecting the closed-loop control........................................................................................906.13.1 Connecting ground.................................................................................................................906.13.2 Connecting the auxiliary voltage ............................................................................................906.13.3 Connecting circuit breakers....................................................................................................916.13.4 Connecting the encoder .........................................................................................................916.13.5 Connecting the external safety loop.......................................................................................92

6.14 Interconnecting optional connections.....................................................................................93

6.15 Fastening the cable ducts with cable ties...............................................................................93

7 Commissioning ...........................................................................................................................................95

8 Operation....................................................................................................................................................97

8.1 Safety instructions for operation.............................................................................................97

8.2 Parameters.............................................................................................................................98

8.3 Setpoint channel and closed-loop control ..............................................................................998.3.1 Setpoint addition ....................................................................................................................998.3.2 Direction of rotation changeover ..........................................................................................1008.3.3 Suppression bandwidths ......................................................................................................1008.3.4 Speed limitation....................................................................................................................1008.3.5 Ramp-function generator .....................................................................................................1018.3.6 Vector control .......................................................................................................................101

8.4 Monitoring and protection functions .....................................................................................1028.4.1 Safety shutdown of the converter.........................................................................................1028.4.2 Speed monitoring with incremental encoder ........................................................................1028.4.3 Uncontrolled stop, EMERGENCY STOP category 0 ...........................................................1038.4.4 Protection function of ground fault detection........................................................................104

8.5 Fault and system messages ................................................................................................1048.5.1 External warnings and faults ................................................................................................1048.5.2 Diagnostics...........................................................................................................................1058.5.2.1 Diagnostics via LEDs ...........................................................................................................1058.5.2.2 Diagnostics via parameters..................................................................................................1078.5.2.3 Indicating and rectifying faults..............................................................................................109

9 Maintenance .............................................................................................................................................111

9.1 Safety instructions for maintenance .....................................................................................111

Table of contents


9.2 Grounding the system ..........................................................................................................113

9.3 Opening the device ..............................................................................................................115

9.4 Preventive maintenance.......................................................................................................1169.4.1 Visual inspections ................................................................................................................1179.4.1.1 Equipment for visual inspections..........................................................................................1179.4.1.2 Checking the isolating clearances........................................................................................1179.4.1.3 Checking hoisting solenoids and security bolts....................................................................1189.4.1.4 Checking the plug connections. ...........................................................................................1189.4.1.5 Checking the cable and screw terminals..............................................................................1189.4.1.6 Checking the thyristor electronics ........................................................................................1189.4.1.7 Checking the filter mats........................................................................................................119

9.5 Maintenance.........................................................................................................................1199.5.1 Replacing a fan ....................................................................................................................1199.5.2 Replacing filter mats.............................................................................................................1229.5.3 Replacing the back-up battery of the AOP30 operator panel ..............................................123

9.6 Cleaning ...............................................................................................................................1249.6.1 Cleaning aluminum parts .....................................................................................................125

9.7 Repairs.................................................................................................................................1259.7.1 Replacing the AVT combination module ..............................................................................1279.7.2 Replacing the snubber circuit capacitor ...............................................................................1289.7.3 Replacing the CompactFlash card .......................................................................................1289.7.4 Replacing the differential pressure monitor..........................................................................1299.7.5 Replacing contactors............................................................................................................1299.7.6 Replacing the current transformer........................................................................................1309.7.7 Replacing the thyristor electronics and thyristors.................................................................1319.7.7.1 Check components of the thyristor assembly ......................................................................1319.7.7.2 Replacing thyristor electronics .............................................................................................1329.7.7.3 Replacing a thyristor ............................................................................................................1339.7.7.4 Disconnecting the fiber-optic cables ....................................................................................1369.7.8 Replacing surge arresters ....................................................................................................1379.7.9 Replacing the DC-link reactor ..............................................................................................138

10 Spare parts ...............................................................................................................................................139

11 Disposal....................................................................................................................................................141

11.1 Disposing of packaging material ..........................................................................................141

11.2 Removing device components and old devices ...................................................................141

A Service & Support.....................................................................................................................................143

A.1 Siemens Industry Online Support ........................................................................................143

A.2 SIOS App .............................................................................................................................144

B Technical specifications and drawings .....................................................................................................145

B.1 Standards and regulations ...................................................................................................145

B.2 Environmental conditions .....................................................................................................146

Index.........................................................................................................................................................149

Table of contents


Tables

Table 3-1 DRIVE-CLiQ interface .................................................................................................................44Table 5-1 Tightening torque for screws.......................................................................................................74Table 5-2 Tightening torques for screw terminals for copper cables without cable lug 1)...........................75Table 6-1 Cleaning agents and grease .......................................................................................................88Table 8-1 Meaning of indicator lights.........................................................................................................105Table 8-2 LEDs of the Sirius safety relay .................................................................................................105Table 8-3 LEDs of the Power Stack Adapters ..........................................................................................106Table 9-1 Technical specifications of the backup battery..........................................................................123Table 9-2 Torques of the capacitor connections .......................................................................................128Table B-1 Standards and regulations ........................................................................................................145Table B-2 Climatic environmental conditions.............................................................................................146Table B-3 Mechanical ambient conditions .................................................................................................146Table B-4 Other ambient conditions ..........................................................................................................147

Figures

Figure 3-1 Example: Components of an air-cooled starting converter for a 6-pulse drive system ...............31Figure 3-2 Schematic diagram: Clamped thyristor assembly .......................................................................32Figure 3-3 AVT combination module ............................................................................................................33Figure 3-4 Example: Power Stack Adapter...................................................................................................34Figure 3-5 Short-circuiting sequence............................................................................................................36Figure 3-6 Example: Components of the motor voltage sensing..................................................................38Figure 3-7 Overview of the voltage sensing circuit .......................................................................................39Figure 3-8 Block diagram of insulation monitoring........................................................................................40Figure 3-9 Operator protection, ground fault detection.................................................................................40Figure 3-10 AOP30 operator panel.................................................................................................................42Figure 3-11 Block diagram of the demagnetization device.............................................................................51Figure 4-1 Two-tier design............................................................................................................................54Figure 4-2 Example: Circuit-breaker control .................................................................................................57Figure 4-3 Laying cables ..............................................................................................................................58Figure 4-4 Example of attaching and displaying the shock and tilt indicators ..............................................61Figure 4-5 Example illustration of centers of gravity.....................................................................................63Figure 4-6 Lifting bar label ............................................................................................................................65Figure 4-7 Securing the lifting rods...............................................................................................................65Figure 4-8 Transporting a transportation unit (still in packaging) with a crane .............................................67Figure 4-9 Example: Cover screw for manual door interlocking ...................................................................69Figure 5-1 Screwing the transport units together..........................................................................................76

Table of contents


Figure 6-1 Shield connection using a clip .....................................................................................................83Figure 6-2 Bridging shield gaps ....................................................................................................................83Figure 6-3 Potential concept.........................................................................................................................84Figure 6-4 Equipotential bonding conductor .................................................................................................84Figure 6-5 Equipotential bonding strip ..........................................................................................................85Figure 6-6 Shield support .............................................................................................................................87Figure 6-7 Example: Equipotential bonding conductor .................................................................................87Figure 6-8 Grounding lug..............................................................................................................................90Figure 6-9 Connection example: HTL encoder, bipolar, with reference signal .............................................92Figure 6-10 Schematic diagram: Fastening the cable ties..............................................................................93Figure 8-1 Parameter types ..........................................................................................................................99Figure 9-1 Schematic diagram for attaching the grounding spider .............................................................114Figure 9-2 Fuse switch disconnector with fuse holder swung out ..............................................................115Figure 9-3 Replacing the fan ......................................................................................................................121Figure 9-4 Example diagram: Replacing filter mats....................................................................................122Figure 9-5 Replacing the backup battery....................................................................................................123Figure 9-6 Example of an AVT combination module ..................................................................................127Figure 9-7 Thyristor rack position ...............................................................................................................131Figure 9-8 Open-ended wrench in the groove of the guide bolt .................................................................135Figure 9-9 Loosening the clamping screw with the socket wrench.............................................................135Figure 9-10 Releasing a fiber-optic cable .....................................................................................................137

Table of contents


Table of contents


Introduction 11.1 About these Operating 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 143).

1.2 Text format features

Text format featuresYou 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.

– 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.


Introduction1.2 Text format features


Safety information 2In 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 devicePlease observe the warning symbols attached to the device. The warning symbols have the following meaning:

Warning symbol MeaningWarning: Voltage

Warning: Hot surface

General warning symbol: Observe the explanations about the hazard on the device labels.

For transportation, observe the "transportation markings (Page 62)" on the device packaging.

2.2 Qualified personnelThe 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 rulesFor your own personal safety and to prevent material damage when carrying out any work, always observe the safety-relevant instructions and the following five safety rules according to EN 50110‑1 "Working in a voltage-free state". Apply the five safety rules in the sequence stated before starting work.

5 safety rules 1. Disconnect the system.

Also disconnect the auxiliary circuits, for example, anti-condensation heating.

2. Secure against reconnection.


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

Danger as a result of high voltages from external suppliesEven if the circuit breaker is open, parts of the converter 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 converter, but can also occur with components that are electrically connected to the converter (e.g. circuit breakers or isolators). Touching live parts can result in death, serious injury, and damage to property.

● Isolate all components that can feed voltage to the converter before commencing work.

Danger due to high voltage in operationWhen 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 converter properly.

● Always observe the "The five safety rules (Page 15)" when carrying out any work.

● Only remove the covers using the methods described by these operating instructions.

● Maintain the converter regularly and correctly.

● After you have switched off the supply voltage, do not carry out any maintenance or repair work until the one minute discharge time for the RC snubber circuit capacitor has elapsed.

Danger as a result of induced voltageRotating 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.

Safety information2.4 Safe handling


Danger due to high auxiliary voltagesHigh auxiliary voltages are still present even after shutdown. Touching live parts can result in death or serious injury.

● Observe the five safety rules when performing any work.

Danger due to hazardous arcingHazards 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.

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 surfacesCertain 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.

Safety information2.4 Safe handling


Risk of burns due to hot anti-condensation heating surfaceWhen 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 accessIf 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.

Shutdown as a result of an incorrect residual current monitoring deviceIf 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.

WARNING

Interference with pacemakers

The functioning of cardiac pacemakers could be impaired by electromagnetic fields. Death or serious physical injury can result.● As a consequence, it is not permissible for people with pacemakers to stand close to the

device.

NOTICE

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.

Safety information2.5 Electromagnetic fields in electrical power engineering installations


Nominated persons in control of electrical installations can find further information on electromagnetic fields under "Information for persons responsible for plants and systems."

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

ESD guidelines

NOTICE

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).

● 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.

Safety information2.6 Components that can be destroyed by electrostatic discharge (ESD)


① Sitting a Conductive floor cover‐ing 1)

d ESD clothing

② Standing b ESD furniture e ESD wrist strap③ Standing/sitting c Wearing of ESD shoes or

ESD shoe grounding strips 2)

f Cabinet ground connection

1) Only effective in conjunction with ESD shoes or ESD shoe grounding strips2) Only effective in conjunction with conductive floor covering

2.7 Information for nominated persons in control of an electrical installation

2.7.1 Proper usageThese 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.

ExplosionsIf 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).

Non-observance of proper usageImproper use of the devices described can result in death, severe injury or material damage.

● Please observe all instructions for proper use.

Safety information2.7 Information for nominated persons in control of an electrical installation


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 converter 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 143)".

See alsoStandards and regulations (Page 145)



2.7.2 Grounding conceptDraw-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 locationThis 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.



2.7.4 Instructions for inverters with no grounding switch

Note

The drive does not have a grounding breaker at the input/output. The system operator must, therefore, ensure that there is sufficient grounding.

2.7.5 Measures for operator protection in electromagnetic fieldsThe 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.

2.7.6 Operator protection measures for demagnetization equipmentAttach a safety note warning of the hazards posed by the demagnetization equipment to all drive components, e.g. to the following:

● Power unit

● Disconnector

● Line-side and machine-side circuit breakers

● Step-up transformer

The safety note must inform personnel that the demagnetization equipment feeds medium voltage into the system even when the circuit breakers are open.

See alsoDemagnetization device for output transformer for starting converters (option L30) (Page 49)



2.8 Residual risksAccording 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.

Pay attention to the following residual risks:

● Unintentional movements of driven machine partsUnintentional 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 emissionsA fault can occur as a result of the following, for example:

– Component malfunctions

– Software errors



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 voltagesHazardous shock voltages can result from the following causes, for example:

– Component malfunctions

– Induction of voltages in moving motors


– Condensation/conductive contamination


● The release of substances and emissions that are harmful to the environment Improper operation or the improper disposal of components can harm the environment.

Safety information2.8 Residual risks


● Damage from pressure build-up during electric arcs in the event of a faultIf 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 faultsThe 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 informationSiemens 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 only form one element of such a concept.

Customer is responsible to prevent unauthorized access to its plants, systems, machines and networks. Systems, machines and components should only be connected to the enterprise network or the internet if and to the extent necessary and with appropriate security measures (e.g. use of firewalls and network segmentation) in place.

Additionally, Siemens’ guidance on appropriate security measures should be taken into account. You can find more information about industrial security by visiting:https://www.siemens.com/industrialsecurity.

Siemens’ products and solutions undergo continuous development to make them more secure. Siemens strongly recommends you apply product updates as soon as available and always use the latest product versions. Use of product versions that are no longer supported, and failure to apply latest updates may increase customer’s exposure to cyber threats.

To stay informed about product updates, subscribe to the Siemens Industrial Security RSS Feed underhttps://www.siemens.com/industrialsecurity.

Additional notes for this product are provided in the Internet and on the CD provided with the device.

Safety information2.9 Security information


"SINAMICS Industrial Security" ManualNotes relating to Industrial Security are provided here (https://support.industry.siemens.com/cs/ww/de/view/109751848/en).

"Security Guidelines for SIMATIC HMI devices" ManualNotes relating to Industrial Security for HMI devices are available here. (https://support.industry.siemens.com/cs/de/en/view/109481300)

Safety information2.9 Security information


https://support.industry.siemens.com/cs/ww/de/view/109751848/en

https://support.industry.siemens.com/cs/ww/de/view/109751848/en

https://support.industry.siemens.com/cs/de/en/view/109481300

https://support.industry.siemens.com/cs/de/en/view/109481300

Description 33.1 Area of application

The current-source DC-link converter is used for continuous speed adjustment of synchronous motors with continuous power above 1 MW. The converter is suitable for four-quadrant operation without additional expenditure. This means driving and braking are possible in both directions.

Starting converterThe output frequency typically lies between 0 and 50/60 Hz. The converter is used as a starting device for the following driven machines, for example:

● Blowers

● Fans

● Compressors

● Gas-turbine sets

● Hydroelectric power generators

● Large synchronous motors on weak power systems

Continuous-duty converterThe output frequency typically lies between 0 and 105 Hz. The converter is used for the variable-speed drive of the following driven machines, for example:

● Blowers

● Fans

● Pumps

● Turbo-compressors

● Reciprocating compressors

● Extruders and mixers

● Continuous-flow conveyors

● Marine propellers

● Drive in rod 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.

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

Touch protection is ensured by means of a housing that conforms to EN 60204-11 and door interlocking. Another door interlocking system is optionally installed, e.g. Castell Lock.

The electromechanical door interlocking system prevents access to the power unit while operational. The following conditions must be fulfilled in order to open the doors: For additional information, see Chapter "Opening the device (Page 115)".

3.2.2 Safety information for IEC 61800-5

DANGER

Insufficient grounding

High voltages can still be present even after shutdown. If live parts are touched, this can result in death or severe injury.

A grounding switch is not installed. The system operator must, therefore, ensure that there is sufficient grounding.

Ensure sufficient grounding during work on the power unit. Further information on grounding can be found under "Safety information for maintenance and repairs".

See alsoGrounding the system (Page 113)

Description3.2 Safety concept


3.2.3 External safety componentsThe safety concept of the converter is supplemented by the following external components:

● Circuit breakerYou can find more detailed information in the section "Circuit breaker (provided by the customer)".

● Input-side transformerWhen an error is detected, the medium-voltage transformer limits the short-circuit current and is configured in such a way that the maximum permissible short-circuit current (see the technical data) is not exceeded.

3.2.4 Protection and monitoring functions of internal components

The internal components of the converter have the following protection and monitoring functions:

● Converter protection based on monitoring systems:

– Current monitoring

– Output voltage monitoring

– Indirect thermal monitoring of the DC link reactor

– Insulation monitoring

– Supply voltage monitoring

– Circuit breaker monitoring

– Monitoring the fans

● Shutdown in the event of semiconductor failure

● Shutdown in the event of control component failure

● Internal protection functions for the control hardware

● Protection against communication failure between the closed-loop control and the power unit

● Anti-condensation heating

Note

For redundant thyristors, shutdown for semiconductor failure only becomes active if redundancy is no longer possible.

3.2.5 Protection and monitoring functions for external componentsTransformer and motor can be monitored in the device. A fast protective shutdown that you can activate for external problems, e.g. short-circuits, is present.

Description3.2 Safety concept


3.3 Power unit

3.3.1 Product features

In the standard version, the power unit has the following product features:

● Simple configuration

● Relatively low semiconductor requirements

● Fuseless design

● Line-side converter

● Motor-side converter

● Voltage actual value sensing on the motor side

● Line-side and machine-side actual current value acquisition

● Line-side and machine-side overvoltage protection with spark-gap-free metal-oxide surge arresters

● DC link reactor for decoupling the line-side converter from the motor-side converter

● Ground fault monitoring system that monitors the entire power circuit, including the transformer secondary winding, motor stator winding, and DC link

● Power cables connected from below (on request: from above)

Description3.3 Power unit


3.3.2 Power unit components

The diagram below shows an example of the typical components of a starting converter for a 6-pulse drive system:

① Circuit breaker② Surge suppressor③ Line-side converter with one or two thyristors in series④ Air-cooled DC link reactor, installed in a cabinet⑤ Motor-side converter with one or two thyristors in series⑥ Static excitation equipment and synchronous motor⑦ Motor voltage sensing (UM sensing)⑧ Ground fault detection⑨ Current transformer in the DC link⑩ Ground fault detection ⑪ Converter transformer⑫ Synchronizing transformer or converter

Figure 3-1 Example: Components of an air-cooled starting converter for a 6-pulse drive system

3.3.2.1 Design of the thyristor stack

1 or 2 thyristor stacks are used for a 6‑pulse bridge. They differ in the number of pick-offs from the heat sinks. The thyristor stacks are equipped with various thyristors and corresponding RC (resistor, capacitor) circuitry. Six thyristors are braced in one clamped thyristor assembly.



Components of the thyristor stackThe clamped thyristor assembly (thyristor stack) consists of 6 thyristors ② and 7 heat sinks ③.

① Set of springs ③ Heat sink② Thyristor ④ Clamping bolt

Figure 3-2 Schematic diagram: Clamped thyristor assembly

The clamped thyristor assembly is pressed together by a set of springs ① with a clamping screw ④ in such a way as to achieve the required contact force.



3.3.2.2 Design of the thyristor modules

Components of the thyristor stack

Each thyristor is connected with a resistor and a capacitor. The resistor and capacitor have the following tasks:

● Where there are several thyristors in series, the resistor and capacitor split up the supply voltage equally.

● If the thyristors are switched off, the resistor and capacitor limit the rate of voltage rise and voltage overshoot.

A thyristor electronics module is assigned to each thyristor. The thyristor electronics are used to fire the thyristors. The thyristor electronics are supplied with energy from the RC circuit.

See alsoThyristor electronics (Page 37)

3.3.2.3 DC-link reactorThe DC link reactor decouples the line-side converter from the motor-side converter and smoothes the direct current. In the event of a fault with overcurrent, the DC link reactor limits the rate of current rise with its inductance, together with the line reactors. Each DC link reactor consists of two magnetically coupled windings wound on an iron core.

3.3.2.4 AVT combination module

The AVT combination module (Actual Value Transmission) processes signals for sensing the actual current and voltage values. The AVT combination module converts analog signals into digital signals. Then the module transfers the signals to the Power Stack Adapter (PSA). The signals are transferred to the PSA via fiber-optic cables.

Figure 3-3 AVT combination module



See alsoVoltage actual value sensing (Page 38)

Ground fault detection (Page 39)

Replacing the AVT combination module (Page 127)

3.3.2.5 Power Stack Adapter

Figure 3-4 Example: Power Stack Adapter

The power stack adapter (PSA) acts as an interface between the power unit and the open-loop/closed-loop controller. The Power Stack Adapter is also where the power unit is electrically isolated from the open-loop/closed-loop controller. The DRIVE-CLiQ serial communication interface ensures the exchange of data between the Power Stack Adapter and Control Unit (CU).

In the Power Stack Adapter, the switching information predefined by the Control Unit is translated into firing pulses (long pulses). The firing pulses are converted to optical signals and sent to the thyristor electronics via fiber-optic cables. This initiates firing readiness in the thyristor electronics and activates a monitoring and interlocking logic circuit. The thyristor electronics then determine the operating status of the thyristor and relays it to the Power Stack Adapter via the checkback fiber-optic cable. The control commands and checkback signals correlate with each other. Any disruption to this relationship, for example an open circuit in an FO conductor or a failed thyristor, is relayed to the open-loop/closed-loop control system as an error message.

3.3.2.6 Current transformerCurrent transformers are used to measure current. The analog output signals from the current transformer are post-processed by the AVT combination module and sent via the fiber-optic cable to the power stack adapter. The primary circuit is separate from the secondary circuit.



3.3.2.7 Fans

The fan is mounted on the cabinet. The fan draws in air through the ventilation slots in the door from the immediate vicinity of the cabinet. The fan blows the air radially into the ambient area. A contactor and a motor protection switch protect the fan against overload.

3.3.2.8 Differential-pressure switchThe differential-pressure switch monitors the independent air cooling and the associated fans. The operating range lies between 100 and 1000 Pa. The differential-pressure switch measures the pressure drop across the heat sink elements. The pressure drop is then compared with the set response threshold. When the fans are in operation and draw the required volumetric flow through the heat sink elements, the response threshold must have been exceeded.

See alsoReplacing the differential pressure monitor (Page 129)

3.3.2.9 Surge arrestersOvervoltages can occur when inductive loads are switched, for example, in the case of transformer disconnections at no load. These overvoltages can pose a danger to the converter. For indoor systems, surge arresters without spark gap are connected in a star configuration between the phases to limit the overvoltages.

3.3.2.10 Door limit switches

Door limit switches monitor the doors. The circuit breaker opens when a door is opened.

The electromechanical door interlocking system prevents access to the power unit while operational. The following conditions must be fulfilled in order to open the doors: For additional information, see Chapter "Opening the device (Page 115)".

3.3.3 Principle of operation

3.3.3.1 Fuseless technologyThe converter is of fuseless design. In the event of a fault, limiting of the overcurrent at the input terminals should be ensured by an appropriate transformer design. In addition, the converter requires matched circuit breakers with a tripping time of 80 ms. The closed-loop control system triggers the circuit breakers. Each circuit breaker must be equipped with a fail-safe OFF contact and an undervoltage coil.



Internal current transformers sense the current and evaluate it electronically. The open-loop and closed-loop control systems prevent an impermissible rise in any overcurrent by switching the line-side converter to inverter operation.

NOTICE

Fault due to incorrect configuration of line supply and transformer impedances

On the line side, the converter is designed for short-circuit-proof operation. Short-circuit-proof operation is only guaranteed if the line supply and transformer impedances are in conformance with the respective specifications in the system-specific data.

If the supply and transformer impedances cannot be maintained, material damage to the converter can occur.

Observe the system-specific values in the "Technical data and drawings" chapter.

Work during braking operation, the motor-side converter (MSR) as rectifiers and the line-side converters as inverters. In the event of a fault during braking, the two motor-side converters immediately switched over to inverter operation. The current in the DC link is suppressed as a result. After that, the circuit breaker is opened.

The leakage reactances of the line transformer or the machine and the supply line from the feeding supply system limit overcurrent in the event of internal short-circuits. In this case, the circuit breaker responds sufficiently quickly to prevent consequential damage.

If there are control errors on the machine side, serious damage to the converter may occur. The short-circuit current is limited by the machine reactances. On designs with output transformers, the short-circuit current is limited by the machine reactance and the transformer reactance (uk). Subsequent faults can be limited by independent disconnecting elements between the converter and the motor. This is not included in the scope of supply.

The thermal utilization of the semiconductors is selected so that, after a short-circuit current, the thyristors still have sufficient blocking ability in accordance with the figure shown below, "Short-circuiting sequence".

The converter can cope with virtually any incident using the fuseless technology and will switch itself off.

Figure 3-5 Short-circuiting sequence



3.3.3.2 Thyristor electronics

Gate control and monitoring system The thyristor electronics consist of the TAS CPLD module (thyristor control and protection, complex programmable logic device).

The thyristor electronics are part of the thyristor control and monitoring system. They work together with the Power Stack Adapter (PSA). The thyristor electronics can control all line-side and motor-side converters which are supplied with voltage by the gate current of the thyristor RC circuit.

The thyristor electronics module has the following tasks:

● They generate the gate pulses for the thyristors.

● Report information on the thyristor status, the thyristor electronics themselves, and the fiber-optic cable connection to the Power Stack Adapter.

A thyristor electronics module is assigned to each thyristor.

A communication peer is required in the form of the Power Stack Adapter. The power stack adapter supplies the optical gating pulses, and evaluates the feedback signals from the thyristor electronics.

Mode of operation of thyristor electronicsThyristor electronics are part of the thyristor control system. The thyristor electronics receive the control signals from the Power Stack Adapter via fiber-optic cables.

The thyristor electronics module generates the following signals:

● Gate pulses

● Checkback signals Checkback signals provide thyristor status and control information. Fiber-optic cables are also used to send these checkback signals back to the Power Stack Adapter.

The Power Stack Adapter evaluates these status checkback signals from the thyristor electronics.With the "Thyristor in command window" status checkback signal and the synchronizing voltage, the offset angle can be determined in a test operation.

The information that can be derived from the correlation between the command and the generated signals includes:

1. Commutation errors

2. Bridge short-circuit

3. Inverter shoot-through

4. Misfiring



3.3.3.3 Voltage actual value sensing

The voltage actual values are measured using AVT combination modules, whose measuring resistors are connected in series. This ensures a high degree of measuring accuracy.

① AVT combination modules② Transformer③ Measuring resistors④ Surge suppressor (only > 3 kV)⑤ 80 kHz power supply

Figure 3-6 Example: Components of the motor voltage sensing



① AVT combination modules② Transformer③ Measuring resistors④ Surge suppressor⑤ 80 kHz power supply

Figure 3-7 Overview of the voltage sensing circuit

3.3.3.4 Ground fault detection

The insulation resistance is monitored against two threshold values. Here, the voltage drop at the resistors between ground and the following artificial neutral points is compared:

● Three-phase current input (line-side)

● Three-phase output (at the motor)

If the warning threshold is exceeded, an alarm is output. If the fault threshold is exceeded, an alarm message is output and the converter is switched off.



Figure 3-8 Block diagram of insulation monitoring① Artificial neutral points

The measuring resistors are current-limiting elements. Using them in conjunction with the surge suppressor provides personnel protection.

① Precision resistors② Surge suppressor and base point resistor

Figure 3-9 Operator protection, ground fault detection

See alsoProtection function of ground fault detection (Page 104)



3.4 Closed-loop control

3.4.1 StructureThe exact arrangement of the components is shown in the layout diagram in the technical specifications.

3.4.2 Indicator lightsThe four indicator lights H21 to H24 are installed at the top in the door of the open-loop and closed-loop control cabinet.

3.4.3 Key-operated switchUse the key-operated switch S11 to select remote control or local operation. The position of the key-operated switch is evaluated using a TM15 terminal module. With the key-operated switch position set to "Local", and once the "LOCAL/REMOTE" key has been pressed on the AOP30, priority for operation is given to the AOP30 or the starter. The AOP30 takes command. In local operation, the ON command in control word 1 and the main setpoint come from the AOP30 or the starter.

3.4.4 Fan in the doorA fan with filter is installed in the control cabinet door. The fan is thermostatically controlled and is switched on when the temperature inside the cabinet reaches approximately 40 °C. The air is drawn in through the lower door filter and blown out using the fan.

3.4.5 Mushroom pushbutton

The mushroom pushbutton is used for safety shutdown. When the safety shutdown function is actuated, the converter shuts down with a fault and a corresponding message appears on the display of the operator panel. Before you restart the converter you must acknowledge the fault.

Description3.4 Closed-loop control


WARNING

Danger due to high voltages after a safety shutdown

In spite of a safety shutdown function, the drive may still be operational or high voltages may still be present.

Residual voltages can result in death, severe injury or significant material damage. The "Safety shutdown" function can neither ensure that the drive stops immediately nor can it ensure that residual voltages do not still exist at the output terminals and within the unit. ● Make sure that the drive no longer rotates and that there are no high voltages present.

3.4.6 Operator panel AOP30

You can use the Advanced Operator Panel (AOP30) for operating, and diagnosing the drive. The AOP30 communicates with the drive via a serial RS-232 interface with PPI protocol. The interface is a point-to-point connection. The AOP30 has the master function in this communication. The connected drive has the slave function.

Functions of the AOP30

Figure 3-10 AOP30 operator panel

The AOP30 has the following features and functions:

● Graphics-capable LCD with the following features

– Green backlighting for plain-text display

– Resolution of 240 x 64 pixels

– Quasi-analog bar-type display for process variables

● Keypad for operational control of a drive



● Numeric keypad for the numeric input of parameter values

● 4 LEDs for indicating the operating state of the drive unit:

– RUN: green

– ALARM: yellow

– FAULT: red

– LOCAL/REMOTE: green

● Help function describing causes of and remedies for faults and alarms

● Function keys for prompted navigation through the menus

● Realtime clock for the time stamping of faults and for setting up simple time controls

● LOCAL/REMOTE switchover for selecting the operating location

● Two-stage security concept to protect against unintentional or unauthorized changes to settings.

● Time and date memory powered by internal battery backup

Functions of the control keys

Calls the main menu of the AOP30.

Calls the "inhibit functions" menu.

Numeric keys for direct entry of values.

Switches between remote and local mode. In local operation, the LED illuminates.

On/offIf no operator inhibit is activated, then the "On" button in local operation is always active. The "Off" button is only active in local operation, and in the factory setting acts as "OFF1".Counterclockwise-clockwise switchoverThe button is only active in local mode.

JOG (Jogging)The key is only in effect in local mode in "Ready to switch on" status (notwhen "operating"). The system is accelerated to the setpoint speed.



Setpoint "increase" and setpoint "decrease".You can enter the setpoint using these buttons. Alternatively, you can enter the setpoint using the alphanumeric keys. Using the numeric key‐pad, any speed ranging between the maximum and minimum speed can be entered.Function keys.These keys have different functions depending on the menu. The respec‐tive function appears in plain text above the key.

3.4.7 Description of the components

3.4.7.1 SINAMICS Control Unit

The CU320 Control Unit is the central control module of the drive's open-loop and closed-loop control system. The connections are wired internally to the customer terminal block.

3.4.7.2 DRIVE-CLiQ interface

Table 3-1 DRIVE-CLiQ interface

Pin Signal name Technical data1 TXP Transmit data +2 TXN Transmit data -3 RXP Receive data +4 Reserved, do not use 5 Reserved, do not use 6 RXN Receive data -7 Reserved, do not use 8 Reserved, do not use A + (24 V) Power supplyB M (0 V) Electronics groundBlanking plate for DRIVE-CLiQ interface: Molex, order number: 85999-3255. The maximum DRIVE-CLiQ cable length is 50 m.

3.4.7.3 Terminal Modules

The Terminal Modules are the central interface for digital and analog inputs and outputs. You can optionally expand the interface to include additional Terminal Modules.



Further information is available in the following documents:

● You will find information on the wiring in the circuit manual in the "Technical specifications and drawings" appendix.

● You can find information on the interfaces and LEDs in the "Supplementary component descriptions" document.

3.4.7.4 Voltage Sensing Module

The VSM10 Voltage Sensing Module measures the actual line voltage values. The connections are wired internally to the customer terminal block.

3.4.7.5 DC/DC converter

DC/DC converters are used to provide a stable and reliable 24 V power supply for the TM15/TM31 terminal module, the circuit breaker, and the SIMATIC S7 (optional).

3.4.7.6 SITOP SelectThe SITOP Select is used to monitor and distribute the load current of the 24 V DC power supply. The SITOP Select has four independent output channels. The output current of each channel can be adjusted from between 3 A and 10 A.

Each channel has its own status signal.

● Channel 1 monitors the power supply for the SINAMICS modules.

● Channels 2 and 3 monitor the 24 V DC power supply in the power unit.

● Channel 4 is used to supply the customer terminals and the circuit breaker.

3.4.7.7 Sirius safety relayThe safety relay monitors the status of the Emergency Off circuit, and is used to implement a safety-related shutdown when dangerous conditions occur. LEDs indicate the operating state and the function.

3.5 Options

3.5.1 Triggering additional circuit breakers (option A04)Additional circuit breakers can be controlled via TM31 and TM15.

Description3.5 Options


See alsoConnecting circuit breakers (Page 91)

3.5.2 Expanded remote control via terminal block (option A06)When using an additional TM31 or TM15 Terminal Module, the quantity structure of control and status signals is extended at the terminal strip.

3.5.3 Motor monitoring (option A09)The motor is monitored via the internal SIMATIC S7. The SIMATIC S7 transfers messages to the Control Unit as message vectors and assigns them to the texts.

3.5.4 Internal synchronizing voltage detection (option A11)The internal synchronizing voltage detection is used to measure the line voltage.

See alsoVoltage actual value sensing (Page 38)

3.5.5 Integrated SIMATIC S7 controller with basic level of equipmentThe option includes the SIMATIC S7 basic equipment level comprising the Control Unit CU315-2 and DP/DP coupler.

3.5.6 Fans in the closed-loop control cabinet (option A20)A fan is integrated in the closed-loop control cabinet. Operation at temperatures about +40°C up to a maximum of +45°C is therefore possible. The fans are not redundant. However, the fan can be replaced in operation. The closed-loop control cabinet can briefly tolerate higher temperatures. Nevertheless, prompt replacement is advisable.

A fan is integrated in the closed-loop control cabinet. Operation at temperatures about +40°C up to a maximum of +45°C is therefore possible. The fans are not redundant. However, the fan can be replaced in operation. The closed-loop control cabinet can briefly tolerate higher temperatures. Nevertheless, prompt replacement is advisable.



3.5.7 Anti-condensation heating for the closed-loop control (A21)The anti-condensation heating is used at low ambient temperatures and high levels of humidity to prevent condensation from forming. The heating is controlled via a thermostat. The heating is externally supplied with power.

3.5.8 Speed sensing for four motors (only starting converters) (option A54)Four SMC30s are used to monitor four motors. This option includes the HUB 20.

The SMC30 (Sensor Module Cabinet-Mounted 30) evaluates motor encoder signals. The sensor module transfers the speed and actual position value to the Control Unit via the internal DRIVE-CLiQ communication interface.

Note

If an encoder fails, the mode can be switched over to "encoderless".

For more information, please refer to “Supplementary component descriptions” on the converter CD.

3.5.9 Dry transformer monitoring (option A72)Alarm and fault messages to the dry-type transformer are evaluated via the additional TM15 module.

3.5.10 Oil transformer monitoring (option A73)Alarm and fault messages to the oil-filled transformer are evaluated via the additional TM15 module.

These are solely binary signals. Up to eight signals are output per step-up transformer or step-down transformer.

3.5.11 Extended dry transformer monitoring (option A74)Binary and analog signals are monitored via the internal SIMATIC S7. The S7 transfers messages to the Control Unit as message vectors and assigns them to the texts. This option contains the following modules:

● Two modules each with 8 analog inputs

● One module with 32 digital outputs

● One module with 32 digital inputs, which is wired via Phoenix spring-cage terminals (cross-section 1.5 mm²)



3.5.12 Extended oil transformer monitoring (option A75)Binary and analog signals are monitored via the internal SIMATIC S7. The S7 transfers messages to the Control Unit as message vectors and assigns them to the texts. This option contains the following modules:

● Two modules each with 8 analog inputs

● One module with 32 digital outputs

● One module with 32 digital inputs, which is wired via Phoenix spring-cage terminals (cross-section 1.5 mm²)

3.5.13 Starting converter for four motors (interfaces for parallel switching device and static excitation equipment) (option A94)

Three additional TM15 terminal modules are used to implement the interfaces with the parallel switching device and the excitation equipment. 16 signals are required for each interface. Thanks to the three additional TM15 terminal modules, four interfaces can be processed.

3.5.14 PROFINET interface (option G24)The CBE20 communication module allows the drive to be networked using PROFINET.

For more information about communication modules, see document "Supplementary component descriptions".

3.5.15 DeviceNet interface (option G23)Using the Anybus X-Gateway communication module, the converter can be connected to the DeviceNet third-party bus system.

The standard version of the drive is equipped with a PROFIBUS interface (slave). The "Anybus-X-Gateway" supplied by HMS Industrial Networks is used to link the drive to the third-party bus system. The X gateway is connected to the CU320 Control Unit using a PROFIBUS cable. The option is supplied with a null modem cable for configuring the X gateway. The gateway is preconfigured to 20 bytes of I/O data. The data size is changed via the configuration interface from a PG/PC (standard PC tool "Windows Hyper Terminal").

Use the "NetTool" supplied by HMS Industrial Networks to configure PROFIBUS. The NetTool is not included in the scope of supply.

3.5.16 Optical link module (option G74)The transition from PROFIBUS to a fiber-optic cable is implemented using the Optical Link Module (OLM).



3.5.17 Diagnostics module PADU8-M (option G76)In addition to the standard PROFIBUS connection for process control, this diagnostics module also allows the exchange of signals via digital and analog inputs and outputs. The signals are transmitted as isolated signals.

3.5.18 Electronic power supply with wide-range power supply unit 1 AC 93 - 253 V, or DC 88 - 360 V (option K71)

The redundant electronics power supply guarantees the internal power supply on practically any supply voltage and even when there are large voltage fluctuations. The possible voltage range is 1-ph 93–253 V AC (50/60 Hz) 20 A or 88–360 V DC 20 A. The internal power supply for the power unit is also derived from the internal power supply of the power unit.

3.5.19 Inductive cable attenuation (option L05)The inductive cable damping is required for high cable capacities at the converter output. High cable capacities at the converter output occur especially for long cable connections.

The inductive cable damping initially limits the commutation, i.e. when discharging system capacities, the rate of current rise dI/dt in the thyristors. For this purpose, dI/dt reactors are installed in the motor-side connection busbars.

If necessary, dI/dt reactors are also installed in the line-side connection busbars.

3.5.20 Demagnetization device for output transformer for starting converters (option L30)The demagnetization of the output transformer is required when starting from standstill. To demagnetize, the demagnetization equipment generates a medium voltage from the auxiliary voltage (e.g. 3 AC 400 V) and feeds this into the system. The demagnetization equipment applies a defined AC voltage to the output transformer, and this AC voltage is then slowly controlled to zero. In this way, the operating point of the output transformer is brought back into the range suitable for making measurements, so that the measured signals required for tracking are transferred without being falsified. This ensures correct position tracking during operation with an output transformer. The excitation current is applied to the standing machine, and the induced voltage is measured (tracked) at the machine terminals. The exact position of the rotor is determined by the position of the three terminal voltages.

During this demagnetization procedure, the demagnetizing medium voltage is fed back into the system via the step-up transformer.

If a step-up transformer is positioned between the converter output and the motor, this measuring-circuit voltage is reduced in the ratio of the transformation ratio. The step-up transformer can become distorted in its magnetic characteristic curve or saturated due to prior activation. As a result, the measuring signal required for tracking may be distorted or may not be transmitted. Incorrect tracking is possible.

In order to cancel the physical effect of the magnetization error, a demagnetization device is used. The demagnetization equipment applies a defined AC voltage to the transformer, and



this AC voltage is then slowly controlled to zero. This brings the operating point of the step-up transformer back into the neutral zone, thus enabling undistorted transmission of the measuring signals required for tracking.

Warning and alarm messages to the transformer are evaluated via the additional TM15 module. These are solely binary signals. Up to eight signals are output per step-up transformer or step-down transformer.

The figure shows the principal outlay of the demagnetization device. The circuit consists of a low-voltage converter with an output filter and a low-power step-up transformer. The demagnetization device has no other interfaces, except the 3AC 400 V infeed, for example.



~

Figure 3-11 Block diagram of the demagnetization device

See alsoOperator protection measures for demagnetization equipment (Page 23)



3.5.21 Cabinet lighting in the control section (option L50)The cabinet lighting is automatically switched on using an integrated motion detector. If the light is switched on by the motion detector, it stays on for three minutes.

3.5.22 Cabinet anti-condensation heating for the power unit (option L55)The anti-condensation heating is used at low ambient temperatures and high levels of humidity to prevent condensation from forming. The heating is controlled via a thermostat. The heating is externally supplied with power.

3.5.23 Dust protection (option M11)To prevent dangerous dust deposits from accumulating in the power unit components, additional filter mats are attached to the outside of the device.

A differential pressure technique continually determines the amount of dust in the filter mats. When the differential pressure switch responds, a fault message is output and the converter is switched off.

3.5.24 Brass cable entry for power and signal cables (option M36)With this option, the cable entry is manufactured out of brass.

3.5.25 Degree of protection IP41 (option M41)The degree of protection is increased to IP41.

3.5.26 Low-noise fan (option M65)Sound pressure is minimized compared to standard setup through the use of special fans.



Preparations for use 4When carrying out any work, carefully observe the information provided in Chapter "Safety instructions (Page 15)".

4.1 Notes for system integrators

4.1.1 Requirements for transformersConfigure suitable converter transformers, i.e. not line transformers, for supplying the LCI power units and the converters of the static excitation equipment. The transformers are electrically dimensioned with regard to the following factors:

● Rated power

● Required overload capability

● Robustness for voltage supply deviations

● Requirements for the fuseless design of the converter with regard to limiting the short-circuit current in the event of a fault

Configure the transformers so that they cover the reactive power dictated by the mode of operation the application requires.

Danger due to an incorrectly configured transformerA short-circuit and simultaneous failure of the closed-loop control system are dangerous if the transformer configuration is incorrect. This can result in death, serious injury or material damage.

● When selecting and dimensioning the transformer, observe the notes regarding the short-circuit behavior for fuseless technology in Chapter Fuseless technology (Page 35).

As well as adjusting the input voltage of the converter to the line voltage, the transformer is also used for electrically isolating the line. The transformer must also supply the required commutation inductance for the line-side converter bridges and for limiting the line harmonics.

The 12-pulse circuit requires a transformer in the form of a two-tier transformer or two individual transformers with two secondary windings offset through 30° electric. The system-oriented open-loop control of the converter may take responsibility for monitoring the line-side transformer for the power unit (option A72 or A73).


Depending on the application and the type of static excitation equipment used, line-side components such as a transformer or line reactors may be required for excitation purposes if their monitoring and control functions are not provided by the converter.

Note

The premagnetization of the converter transformer is not part of the converter.

See alsoDry transformer monitoring (option A72) (Page 47)

Oil transformer monitoring (option A73) (Page 47)

4.1.2 Selection and configuration of multi-winding transformersMulti-winding transformers supply converters which are connected separately, in parallel, or in series. In general, transformers are configured for a line voltage range of ±5% in accordance with IEC 60076-1 (they may be configured differently on request).

Coupling factorEach converter causes current harmonics as a result of non-sinusoidal input currents and commutation processes. These current harmonics distort the voltage, which results in a deformation of the supply voltage for subsequent windings. This can cause a malfunction in the case of controlled line-side converters. In critical cases, ensure that the degree of coupling is less than 10 to 15% and that the degree of decoupling is between 85 and 90%.

Design of the transformer winding

① CoreFigure 4-1 Two-tier design

Preparations for use4.1 Notes for system integrators


Transformers for start-up operationFor short-time operation, the converter as well as the associated step-down and step-up transformer (if being used) are utilized to a higher degree. In the case of starting converters in the LCI design version, usually only the DC link reactor is affected. If just one or two motors have to start up consecutively, the transformers can be significantly overloaded. In this case the only limits are thermal load capacity of the winding and the iron core. When specifying/ordering the transformer, mention heavy-duty starting (>> 2 min).

When using a step-up transformer, the following applies: Starting at zero speed, the transformer can transfer up to 100% converter output current for a specific time. However, in order to avoid the risk of saturation when starting from standstill, at low speeds, the converter current is initially reduced to approximately 50% (no heavy-duty starting).

A transformer only becomes saturated when a certain voltage-time area is exceeded. This is only indirectly linked to the current to be transferred, because the current that is fed in causes a certain voltage (at least i*r), which also leads to saturation after the relevant time.

Transformer specificationFor the transformer, as minimum take into account the following specifics:

● Converter transformer for a B6C bridge

● Percentage of the current harmonics

● Voltage load

● Control angle for feedback (90° or 40° electrical)

● Transformation ratio during idling

● Short-circuit voltage uK for the step-up transformer

4.1.3 Requirements for the circuit breaker provided by the customer

To ensure adequate protection for converters, the circuit breaker provided by the customer must fulfill the following conditions:

● The tripping time of the circuit-breaker must not exceed 80 ms.

● The circuit-breaker must be equipped with an undervoltage release. The undervoltage release (undervoltage release coil) is controlled via the release circuit, into which the "undervoltage release" output of the converter must be integrated as well. The auxiliary voltage from the switchgear (this is a reliable supply) is used as the supply.

Note

In power converters, the undervoltage release is not normally supplied from voltage transformers that are connected to the main supply network. As a consequence, an undervoltage condition in the main line supply does not result in shutdown/trip by the switchgear or the voltage transformer.

● Avoid additional delay times when controlling the circuit breaker. All commands from the converter to the circuit breaker must act directly without intervention of coupling relays.



● There must be a checkback signal for each of the the circuit breaker statuses CLOSED and OPEN. The checkback signals must occur promptly, typically within a second.

● Provide time-overcurrent protection.

● Under no circumstances may the circuit breaker be electrically or mechanically externally closed. A mechanical interlock of the manual ON command at the circuit breaker prevents destruction of the converter as a result of an uncoordinated switch-on operation.

● In the event of external tripping of the circuit breaker, prevent the converter from shutting down with unattributable follow-up messages. Therefore, ensure that the converter is definitively switched to current-free with a "leading contact". This must happen before the main contacts of the circuit breaker open. A corresponding message is also generated by the converter open-loop controller ("external tripping of circuit breaker").

● Many circuit breakers do not have a mechanically leading contact. You can implement the contact in various ways:

– If you are using a digital over-current relay, you must use it to detect all shutdown conditions of the circuit breaker internally and externally (e.g. Buchholz fault). You must program two tripping contacts with equivalent functions. One tripping contact is wired to the "leading contact" input of the converter. The second tripping contact is wired to the undervoltage release of the circuit breaker.

– The voltage at the undervoltage coil is queried via an optocoupler. The output of the optocoupler is wired to the "leading contact" input of the converter. We recommend using a Phoenix ST-OE 3 optocoupler with 24 V short-circuit-proof DC voltage output. The exact type will depend on the auxiliary voltage of the switchgear (input data of the optocoupler).

Lack of intrinsic device protection for the circuit breakerIf the fuseless version of the converter is being used and the circuit breaker does not have any additional intrinsic device protection, this can result in damage to the power unit.

Ensure that the circuit breaker has additional intrinsic device protection. The intrinsic device protection must be switched off within 100 ms of a short-circuit current at the latest.



1

2

3

4

B6MSR

B6MSR

SM

2,3 kV bis 36 kV, 3 ~ 50/60 Hz

1

2

3

4

Figure 4-2 Example: Circuit-breaker control



4.1.4 Requirements for cables

Power cable1. Only shielded medium-voltage cables may be used as power cables. Due to the low

capacitance, it is preferable to use single-phase cables, e.g. Protothen N2XS2Y. You can also used armored cables of the type that are standard in some regions/industries. You should, however, observe the dimensioning criteria regarding maximum capacitances and inductances.

2. Lay the cables in a 3-phase bundle.

a) Laying the cables in a 3-phase bundleb) Laying three parallel cables (to accommodate each phase)

Figure 4-3 Laying cables

The method used for laying the parallel cables is not critical as far as EMC is concerned. However, to avoid damage in the event of a short-circuit current, you should fasten the cables in the appropriate way.

3. Take into consideration the line-to-line voltage to ground (√3* U) when selecting the cable voltage class. The converter can run even if a ground fault is present. In this case, the voltage to ground is the line-to-line voltage.

4. Where the current is concerned, take into account the rms value for dimensioning purposes, as the rms value also contains the harmonic currents.

Cable capacitance and inductanceCable capacitances and inductances can influence the commutation. The cable capacitance has an influence on the dl/dt limit required (toroidal cores). Add the cable inductance to the effective motor inductance.

The project-specific dimensioning provides the max. permissible capacitance and the max. permissible inductance with respect to the commutation process. Both specifications can be found in the "Plant-specific data". Pay attention to this information.

Determining the effective values in the case of commutation

Effective cable capacitance in the case of commutation:C = C’ (in μF/km) * cable length * number of parallel cables / 2



The value in the reference for the capacitance per unit length is specified in relation to ground. During commutation, the capacitances subsequently switch in series via ground, and capacitances switched in series produce a total capacitance of 1/2 (factor 0.5). C’ refers to the operating cable capacitance.

Effective cable inductance in the case of commutation:L = L’ (in mH/km) * cable length / number of parallel cables

The value in the reference for the conductor inductance refers to one phase. L’ refers to the inductance per unit length of a conductor in a single-phase alternating current system. The inductance per unit length can be calculated with the assumption that one conductor is used as the forward line and the other is used as the return line.

You can connect the following maximum number of cables:

● Six parallel cables per phase with 630 mm2 at one water-cooled converter

● Four parallel cables per phase with 240 mm2 at one air-cooled converter

Signal cables and other cablesComplete, pre-assembled cable sets are supplied as standard for cabling the power unit, static excitation equipment, and closed-loop control. The cable-related cabinet distances can be specified for the project.

Shield supportObserve the notes in Chapter "Connecting the power unit (Page 87)".

ReferenceHeinold, Lothar (publ.): Kabel und Leitungen für Starkstrom I. Publicis Corporate Publishing 1987

4.2 Requirements when mounting and installing the device

4.2.1 Requirements for installation locationThe cabinet units are suitable for installation in general operating areas (to DIN EN 60146-1-1 / VDE 558 T11 and DIN EN 50178 / VDE 0160 (IEC 62103), degree of contamination 2; without conducted contamination). For this reason, SINAMICS devices must be protected in such a way that they cannot be touched directly when they are being installed in general operating areas.

The operating areas must be dry and free of dust. The air supplied must not contain any electrically conductive gas, vapors, or dust which could impair operation.

For information about permissible ambient and installation conditions, see the "Technical data and drawings" section.

Preparations for use4.2 Requirements when mounting and installing the device


4.2.2 Requirements placed on the levelness of the floorEnsure that the following requirements are satisfied:

● The floor is completely horizontal and flat.

● The doors can be opened and closed. The locking systems function correctly.

● Flat parts and components, e.g. doors and side panels, seal correctly. Only then is the degree of protection maintained.

4.3 Inspections when receiving the delivery

4.3.1 Checking shock and tilt indicators

The purpose of shock and tilt indicatorsThe unit is equipped with shock and tilt indicators to monitor for damage during transit. It is essential that you check the shock and tilt indicators before commissioning the unit.

WARNING

Tripped shock and tilt indicators

Safe operation of the device is not guaranteed if the shock or tilt indicator has tripped (responded)

This can result in death, serious injury or material damage.● If one of the indicators has tripped, do not perform any commissioning.● Inform the Technical Support. Only specialist Siemens technicians can recommend

appropriate measures.

See alsoService & Support (Page 143)

Preparations for use4.3 Inspections when receiving the delivery


Location and display of the indicatorsYou can find the indicators at the following locations:

● The tilt indicators are located in the upper third of the cabinet. If the arrow above the line ① is blued, the tilt indicator has tripped.

● The shock indicators are located at the bottom of the cabinet. If one or both arrows ② are black, the shock indicator has tripped.

Figure 4-4 Example of attaching and displaying the shock and tilt indicators

4.3.2 Checking the load handling attachmentsCheck the load suspension devices before lifting and transporting (such as lifting lugs and eyebolts) and the lifting gear:

● Inspect the load suspension devices attached to the equipment for possible damage. Replace load suspension devices if they are damaged.

● Before use, check that the load suspension devices are correctly attached.

● When lifting, use only approved and undamaged lifting gear of sufficient rated capacity. Check the lifting gear prior to its use.

WARNING

Load suspension devices and lifting gear damaged

If the load suspension devices and lifting gear are damaged or not correctly secured, the equipment may be dropped during lifting and transportation. This can result in death, serious injury or material damage.

Inspect the load handling attachments and lifting gear before use.

Preparations for use4.3 Inspections when receiving the delivery


4.4 Transportation

The terms are defined as follows in the following part of the instructions:

● "Transportation unit" refers to the unit before it has been unpacked

● "Cabinet" refers to the unit after it has been unpacked

4.4.1 Transport markingsThe packing differs depending on the transport type and size. If not otherwise contractually agreed, the packaging corresponds to the packing guidelines for International Standards for Phytosanitary Measures (ISPM).

Note the symbols which appear on the packing. These have the following meanings:

Top Fragile material Keep dry Keep cool Center of gravity

Do not use hand hook

Attach here

4.4.2 Transport requirements● Persons driving cranes and fork-lift trucks must hold appropriate licenses.

● You must observe the specifications to avoid transport damage to the enclosure and you must maintain the permissible climatic conditions during operation in accordance with IEC 60721-3-1/2/3. Please also observe the "Technical specifications" instructions.

● For lifting the device, always use certified and adequately dimensioned cable guiding and spreading devices that are in absolutely perfect condition. The weight of the device is stamped on the rating plate. Carefully check the cable guide and/or spreading devices before using them.

● When lifting, refer to the information on the lifting plate or in "Technical data and drawings."

NOTICE

Vibrations

Significant vibration during transportation and shocks when setting down can damage the equipment.

Avoid vibrations and shocks.

Preparations for use4.4 Transportation


4.4.3 Observe center of gravity

WARNING

Non-observance of center of gravity specifications

The cabinet is heavy. The center of gravity can be in the upper half of the cabinet. The unit can tip over if you transport it incorrectly – or if you use transport equipment that is not permitted for the purpose. This can result in death, serious injury or material damage.● Ensure that only trained personnel transport the device with approved transport equipment

and lifting tools. ● Observe the center of gravity specifications. A label or stamp is attached to each

transportation unit and precisely shows the center of gravity of the cabinet.● Do not tilt the device or allow it to fall.

The following figure shows the centers of gravity as an example: Carefully note the centers of gravity when performing any lifting or installation work.

Figure 4-5 Example illustration of centers of gravity

4.4.4 Transport with a fork-lift truck

WARNING

Danger when a transport unit/cabinet tips over

If the forks are too short, this can cause the transport unit/cabinet to tip over resulting in death, serious injury, or damage to the cabinet. ● The forks of the truck must protrude at the rear of the transport pallet. The floor panels of

the transport units will not support a load.● Only use fork-lift trucks approved for this purpose to transport the units.

When the transport units are transported or moved with a fork-lift truck, the force is absorbed through the transport pallet.

Observe the following points for safe transport:

● Transport the transport unit/cabinet with the greatest care.

● Choose the lowest transport height possible. The pallet may not touch the ground. Always transport the cabinet in an upright position.

● Avoid driving over bumps.



4.4.5 Transport with a crane

WARNING

Danger due to incorrect transport

If the transport unit is not properly transported with a crane, the transport unit/cabinet could fall or tip over This can result in death, serious injury or material damage.● Make sure that you read the safety information about transportation and the information

provided on the transport unit (e.g. center of gravity specifications).

WARNING

Danger due to unsuitable cross-arms

If inappropriate cross-arms are used, the transport unit or cabinet can tip over. This can result in death, serious injury or material damage.● Observe the specifications provided in DIN EN 13155 on cross-arms.

Observe the following points for safe transport:

● When using a crane to transport the equipment, keep to the permissible lifting capacity. Pay attention to the center of gravity position.

● If the cabinet center of gravity is off-center, use suitable lifting equipment, e.g. a lifting beam.

● If the cabinet has eye hooks, use them. In such cases, do not use any lifting rods.

4.4.6 Using lifting rods

During transportation with a crane, force is absorbed by the supporting frame of the cabinet. The supporting frame remains on the unit. The device is mounted at the installation site via the supporting frame.

NoteLifting bars

The lifting bars are not included in the scope of delivery.

WARNING

Danger if the device falls

Inadequately dimensioned lifting rods are liable to bend or break. As a consequence, the device can fall from the crane. This can result in death, serious injury or material damage.● Use suitable lifting rods for transporting. The weight of the cabinet is indicated on the rating

plate.



NOTICE

Damage due to incorrect lifting

If the transport unit is lifted incorrectly, this can damage the decorative trim, cabinet doors, or fans.● Protect the cabinet and protruding parts against damage.● Always lift the transport units with the appropriate spreading devices or hoisting tackle.

Procedure1. If there are several holes, select which holes to use based on the center of gravity.

2. Push the lifting bars through the holes.

Figure 4-6 Lifting bar label

3. Place the sling ropes on the lifting bars so they are close to the cabinet. Secure the ends of the lifting bars using the splint.

Figure 4-7 Securing the lifting rods

4. To lift the transport unit, use single sling ropes or two ropes with a cross stitch. Attach the crane rope to the lifting rods so it is close to the cabinet.

5. Lift the cabinet. Avoid shifting the center of gravity or distorting or damaging the cabinet. When suspended, the cabinet must be parallel to the ground.



4.4.7 Transporting transportation units packed in boxes

Transportation with the fork-lift truck

WARNING

Danger when a transport unit/device tips over

If the forks are too short, this can cause the transportation unit/the device to tip over resulting in death, serious injury, or damage inside the cabinet. ● The forks of the truck must protrude at the rear of the transportation unit. ● Only use forklifts approved for the purpose of transporting the devices.

Transportation with the crane

WARNING

Danger due to falling transport unit/cabinet

If the lifting gear or load suspension devices were to fail, the transportation unit/the cabinet could fall. Death, serious injury, or material damage can result.● Do not stand underneath or near to a raised load.

To protect the boxes against pressure, use sufficiently long rope and a spreader beam. Please proceed as follows:

1. Attach the rope/cable to the pallet as shown in the following diagram.

2. Attach the rope/cable to the spreader beam ① and the crane hook.



3. Pay attention to the center of gravity imprinted on the box ② and the imprinted position of the ropes ③.

4. Carefully raise the transportation unit.

① Spreader beam② Center of gravity③ Imprinted position of the rope

Figure 4-8 Transporting a transportation unit (still in packaging) with a crane

4.5 Unpacking

4.5.1 Removing the packaging

NOTICE

Incorrect storage of unpacked devices

Proper packaging ensures that the equipment is protected. Unpackaged equipment may be damaged if it is stored or out of service over a long period.

Carefully observe the instructions for storage in Chapters "Storage" and "Technical data and drawings". Remove the packaging immediately prior to installation.

The units are packed by the manufacturers in accordance with the order.

Preparations for use4.5 Unpacking


In order not to damage open mounting parts (e.g. pipes and busbars), take the following measures when removing the foil and the load securing devices:

● Remove the foil and load securing devices carefully.

● Remove the packaging immediately prior to installation. Protect the cabinets against dust until they have been commissioned. To do this, cover the ventilation openings and keep the doors closed.

● Do not remove the safety instructions and center of gravity specifications from the cabinet.

4.5.2 Removing load securing devices

WARNING

Fixing materials can come under tensile stress

If fixing materials are released suddenly during opening and people get in the way, this could result in bodily injury or death.

Release the retaining straps before opening. Stay out of the way of the impact direction of the retaining straps.

NOTICE

Improper removal of the load securing devices

The load securing device protects the cabinet from any damage. If you remove the load securing device improperly, the cabinet may sustain damage.

Correctly remove the load securing device.

To extract the load securing device, proceed as follows:

1. Remove the retaining straps.

2. Remove the spacers such as wooden wedges, air cushions, etc.

4.5.3 Lifting the cabinet off the transport palletUse a crane to lower the transportation units from the transport pallets and transport them to the installation site. Observe the guidelines described in the section "Transport with a crane."



4.5.4 Opening doors in preparation for use

NOTICE

Incorrectly opening the doors

If you incorrectly open the doors, then this can damage the locking mechanism.● When opening the doors, follow the steps described.● You must replace a damaged locking mechanism before commissioning, which will be

charged for. Contact the service center in this regard. You can find the relevant contact person under "Service & Support".

When the device is shipped, the doors are closed. To open the doors with the device in a no-voltage condition, proceed as follows:

1. A screw marked with an adhesive label is located on the door. Under the screw you will find the opening for manually opening the doors. Loosen this screw.

Figure 4-9 Example: Cover screw for manual door interlocking

2. Insert a screwdriver into this opening.

3. Turn the door handle until you feel resistance.

4. Remove the screwdriver from the opening.

5. Open the doors.

4.5.5 Checking the shock and tilt indicators inside the cabinet.Shock and tilt indicators are also located inside the cabinet. Check these as soon as you have unpacked and opened the device. To perform the check, proceed as described in "Checking shock and tilt indicators"

NOTICE

Material damage caused by transport indicators remaining in the device during operation

If transport indicators remain in the device during operation, material damage can result when they fall off – or as a result of temperature damage.● Remove the transport indicators before commissioning. Remove any adhesive residue

from the transport indicators using methylated spirits.



See alsoChecking shock and tilt indicators (Page 60)

4.6 Storage

4.6.1 Storing a deviceIf you are not going to commission the device immediately after delivery, ensure that it is stored correctly.

Preconditions and preparations● Store goods only in undamaged packaging. Unpack the goods if the packaging is damaged.

Correctly store the goods corresponding to the type of goods.

● Repair any damage to the packaging before putting the equipment into storage insofar as this is necessary to ensure proper storage conditions.

General instructions for storageWherever possible, store the device in a storage room. The place of storage must satisfy the following general conditions:

● Select a sufficiently sized dry and horizontal place of storage that is above flood level and free of vibration (veff ≤ 0.2 mm/s).

● The place of storage must be well ventilated as well as free of dust and frost.

– Provide protection against extreme weather conditions.

– Optimum temperatures are between 10° C (50° F) to 50° C (120° F).

– Room temperature should be approx. 10 °C (14 °F) above the outside temperature.

– The temperature may not fall below ‑20 °C (-4 °F).

– For lower temperatures, agree on suitable measures together with Siemens.

– Relative humidity should be less than 60%.

– The floor of the place of storage must be sufficiently strong. Do not exceed maximum permissible floor load levels or storage compartment load levels.

– The ambient air must not contain any harmful gases.

● Protect the device against shocks and humidity.

● In order to ensure protection against ground moisture and water, place the equipment and crates on pallets, wooden beams or foundations.

● Ensure that the air circulation under the equipment is not impeded.

– Place wooden spacer blocks between the covers and the device.

– Do not place covers or tarpaulins completely around the equipment on the floor.

Preparations for use4.6 Storage


NOTICE

Improper storage

Incorrect or excessively long storage can damage the equipment.● Do not store the device outdoors.● Observe the specified conditions for storing the device.● Ensure that it is not stored for longer than the permissible maximum of two years.

Protection against humidity ● If a dry storage area is not available, then take the following precautions:

– Wrap the device in humidity-absorbent material. Then wrap the device in film so that it is airtight.

– Place a humidity meter that can be read from outside inside the film wrapping. Observe the values provided in the technical specifications on relative humidity. Check the values regularly using the humidity meter.

– Inspect the device regularly.

4.6.2 Storing fans

NOTICE

Improper fan storage

Even if the fan is not used, the bearing grease ages. The utility of the fan can be impaired.

Rotate the fan at least once a year. Do not store the fan for longer than two years before commissioning.



Mounting 55.1 Safety instructions for installation

When carrying out any work, carefully observe the information provided in Chapter "Safety instructions (Page 15)".

Material damage caused by improper installationThe devices can be damaged through improper installation.

● Install the devices as described in the following sections.

● Take note of the ambient temperatures stated in the technical specifications.

● Avoid any inadmissible load and stress.

Danger due to deposits of dust during installationWhen performing mounting and installation work, dirt can accumulates inside the device when the doors are open. Dirt deposits can can mean that the requirements relating to cleanliness are no longer fulfilled. If operated with dirt inside the device, then this can result death, serious injury and material damage.

● Therefore, remove dirt deposits after installation. Then keep the doors closed.

● In the event of contamination from conductive dust particles (e.g. from welding work), professional cleaning will be required. Contact the service center in this regard.

Danger due to defective sealsWhen working on the device, seals at the doors, roof panels as well as front, rear and side panels can be damaged. Operation with defective seals can result in death, serious injury or material damage.

● Replace the defective seals before commissioning. Observe the environmental conditions stated in the technical data.

Damage caused by foreign bodiesIf foreign bodies are left in the device after installation and maintenance work, this can cause damage when the device is switched on.

● Before switching on, check as to whether there are any foreign bodies in the device. Remove any foreign bodies.


Damage caused by incorrectly opening doorsIf you incorrectly open the doors, then this can damage the locking mechanism.

● Open the doors as described in Section "Preparing for use".

See alsoOpening doors in preparation for use (Page 69)

5.2 Tools requiredYou require the following tools for mounting and installation:

● Wrench or socket wrench, width across the flats 10, 13, 16/17, 18/19

● Allen key, size 8

● Torque wrench up to 50 Nm

● Screwdriver, size 2

● Torx T20 and T30 screwdrivers

5.3 Torques

The following table contains the default values. If the replacement of a component requires different torques, they are specified in the associated sections.

Table 5-1 Tightening torque for screws

Screw type Soft materials S31 Hard materials S22 Hard materials S13

nm in - lb nm in - lb nm in - lbM3 0.8 7.1 1.8 15.9 1.3 11.5M4 1.8 15.9 3.9 34.5 3.0 26.6M5 3.0 26.6 7.8 69.0 6.0 53.1M6 6.0 53.1 13.0 115 10.0 88.5M8 13.0 115 32.0 283 25.0 221M10 25.0 221 65.0 575 50.0 443M12 50.0 443 115.0 1020 88.0 779M16 115.0 1020 270.0 2390 215.0 1900

1 Examples of soft materials are Cu, Al, CuZn cable entries, laminate materials, plastics, cast resin post insulators, press nuts, welding nuts, blind rivet nuts, and cage nuts.2 Hard materials S2 are materials with friction-enhancing washer components, e.g. a contact washer.

Mounting5.3 Torques


3 Hard S1 materials include steel, for example.

Table 5-2 Tightening torques for screw terminals for copper cables without cable lug 1)

Screw type Set screws andheadless screws

Head screws with slit

Head screws with hexagon profile

nm in - lb nm in - lb nm in - lbM2 - - - M2.5 0.25 2.2 0.5 4.4 0.5 4.4M3 0.3 2.7 0.6 5.3 0.6 5.3M3.5 0.5 4.4 1.0 8.9 1.0 8.9M4 0.8 7.1 1.3 11.5 1.3 11.5M5 1.0 8.6 2.5 22.1 2.5 22.1M6 1.3 11.5 3.0 26.6 3.5 31.0M8 1.8 15.9 3.9 34.5 7.2 63.7M10 - - 4.8 42.5 13 115M12 - - - - 18 159.3M16 - - - - 30 265.5

Observe the tightening torques of the terminal manufacturer and the test torques according to DIN EN 60999-1, VDE 609-1

5.4 Screwing the transport units together

NOTICE

Material damage caused by mechanical pressure on components

Stress that occurs during transport may exert mechanical pressure on the components.

Material damage can result.● Line the cabinets up precisely with each other in order to avoid shearing forces when the

base units are screwed together.● Install the converter only on a level and horizontal surface.

Ensure that access to the holes in the bottom of the cabinets is unobstructed. Remove the guard covers.

Mounting hardwareTo screw the transport units together, you will need the following mounting hardware:

● Self-adhesive sealing strips

● Hexagon nut M8

Mounting5.4 Screwing the transport units together


● Contact washers

● Threaded pin M8 x 15.5

ProcedureTo screw transport units together, proceed as follows:

① Holes for threaded pins② Self-adhesive sealing strips

Figure 5-1 Screwing the transport units together

1. Affix the self-adhesive sealing strips ②.

2. Align the cabinets.

3. Insert the threaded pins through the holes ①.

4. Attach the contact washers to the threaded pins.

5. Screw the transport units together using the nuts with a torque of 32 Nm.

5.5 Connect to the foundationFour holes for M12 screws are provided on each cabinet panel to secure the cabinet to the foundation. Information on mounting holes and their fixing dimensions are specified in the dimension drawing.

Install the transport units in accordance with the specifications provided in the accompanying dimension drawings. When doing this, maintain the specified distance between the top of the cabinet and the ceiling.

5.6 Mounting fansYou must mount the fans, if, for logistical reasons, the fans were separately supplied. Proceed as described in the section "Mounting fans" of Chapter "Replacing fans".

Mounting5.6 Mounting fans


See alsoReplacing a fan (Page 119)

5.7 Ensuring cooling airThe cooling air for the power unit is drawn in from the front through the ventilation grilles in the cabinet doors. The warmed air is expelled above the fan through the perforated top cover or the ventilation grilles in the top cover.

Make sure that the air that is supplied is free of dust or any other electrically conductive material. Avoid environmental conditions that could cause condensation. Seal the cable connector panels from the top.

Mounting5.7 Ensuring cooling air


Mounting5.7 Ensuring cooling air


Electrical connection 6Note

Control and signal lines must always be connected according to the circuit diagrams supplied with the unit. Detailed information about connecting the components is given in the interconnection diagram.

6.1 Safety instructions for electrical connection


Danger due to incorrectly sealed cable entryIf the cable entry is not correctly sealed, it is possible that the device no longer complies with the requirements associated with the specified degree of protection.

Operation with an insufficient degree of protection can result in death, serious injury and material damage.

● To maintain the degree of protection, after connecting the cable, immediately seal the cable entries so they are air-tight.

Danger caused by changing the floor panel or the roof panelIf you make any changes to the floor panel or the roof panel in order to modify the cable entry, the changes may mean that the requirements related to the specified degree of protection are no longer complied with. If there are any holes in the floor or roof panel, then animals and vermin, for example, can get into the device while it is operational.

When operated with an insufficient degree of protection, this can result in death, serious injury and material damage.

● To maintain the degree of protection, after installation, immediately seal the holes so they are air-tight.




Injury caused by short circuitDamaged cables, or their improper routing, can cause damage to property and personal injury.

● Only use cables that are completely intact and not damaged. Correctly route the cables. Do not interchange input and output terminals.

● Make sure that a short-circuit cannot occur on the power cables due to failure of the insulation as a result of incorrect cable installation.

● Check the electrical connections after service work.

Danger caused by incorrect cable routingFailure to use the supplied cable ducts for laying the cables can lead to flashovers. This can result in death, serious injuries or material damage.

● To connect the cables between the cabinets, use the cable ducts and the cable entries on the roof. Lead the cables from here to the next cabinet.

Material damage caused by parts that can be magnetizedThe use of magnetizable parts, e.g. ferrous cable clamps, is not permitted. Using parts and components that can be magnetized can cause damage.

● Only use parts that consist of non-magnetic material.

Material damage caused by high transition resistancesCables connected to the connection point that are not in compliance with the applicable regulations represent a high electrical transition resistance that can cause thermal damage (contact erosion) during operation.

● Tighten the screws with the required torque.

Damage caused by incorrectly shrinking cable terminations If you are connecting the mains and motor-side power cables, when shrinking the cable terminations, other control lines and fiber-optic cables in the surrounding cable channels can become damaged.

● When shrinking, ensure not to damage cables in the surrounding cable channels.

Electrical connection6.1 Safety instructions for electrical connection


Damage caused by incorrectly shrinking cable terminations When connecting line and motor-side power cables, when shrinking the cable terminations, other control cables can be damaged in the adjacent/surrounding cable ducts.

● When shrinking, ensure not to damage cables in the surrounding cable channels.

Material damage caused by incorrectly opening doorsIf you incorrectly open the doors, then this can damage the locking mechanism.

● Open the doors as described in Section "Preparing for use".

6.2 Note on shielded cables

Note

We recommend using shielded cables. Unshielded cables can transfer disturbances to the control and signal lines and lead to malfunctions in the drive.

Note

To ensure trouble-free operation without interference or disturbances, route the power cables and signal lines separately. Interference, for example, will result in the device not behaving as expected.

When connecting and routing power and signal cables, observe the instructions contained in the "Electromagnetic compatibility" section.

6.3 Electromagnetic compatibilityThe following fundamental information and guidelines facilitate compliance with the EMC directives.

Note

We recommend that EMC is planned for the entire plant.

Cabinet installation ● Connect painted or anodized metal components using contact washers or remove the

insulating layer.

● Use unpainted, de-oiled mounting plates.

● Establish a central connection between ground and the protective conductor system (PE protective conductor).

Electrical connection6.3 Electromagnetic compatibility


Cable installation ● Cables that are subject to or sensitive to interference should be laid as far apart from each

other as possible.

● The distance between the power cable and the signal cable should be at least 20 cm. Device-specific data apply for power cables. You can find further information on power cables under "Connecting power cables".

● When the cables are routed close to ground potential, the immunity to interference is increased. For this reason, you are advised to lay these cables along edges and at ground potential.

● Ground the reserve cores on at least one end.

● In order to avoid additional locations where interference can be coupled in, long cables should be shortened or routed where there is little interference.

● If conductors or cables conduct signals of different classes, then the conductors and cables must cross at a right angle. This especially involves sensitive and noisy signals.

– Class 1: Unshielded cables for ≤ 60 V DCUnshielded cables for ≤ 25 V ACShielded analog signal cablesShielded bus and data cablesOperator panel interfaces, incremental/absolute encoder cables

– Class 2:Unshielded cables for > 60 V DC and ≤ 230 V DCUnshielded cables for > 25 V AC and ≤ 230 V AC

– Class 3:Unshielded cables for > 230 V AC/V DC and ≤ 1000 V AC/DC

– Class 4: Unshielded cables for > 1000 V AC/DC

Shield connection ● Do not use cable shields to conduct current. It is not permissible that the cable shield is used

as neutral or PE conductor.

● Apply the cable shield so that it covers the greatest possible surface area. Use ground clamps, ground terminals or ground screw connections.

● Avoid extending the cable shield to the grounding point using a wire. This reduces the shield effectiveness by up to 90%.



● Attach the cable shield to a shield busbar directly after the line inlet into the cabinet. Insulate the shielded cable without any interruptions. Route the cable shield up to the device connection.

① Shield busbar② Shielded cable③ Mounting clip

Figure 6-1 Shield connection using a clip

NOTICE

Damaged or incorrectly mounted cable shielding

Incorrect connection or damaging of the cable shield can impair the function of the system.● Handle the cable shield carefully.● Ensure that the cable shield is correctly connected.

● Bridge shield gaps (at terminals, circuit-breakers, contactors, etc.) with minimum impedance and through the largest possible surface area.

① Shield busbars② Cables③ Terminals

Figure 6-2 Bridging shield gaps



I/O connection ● Create a low-impedance ground connection for additional cabinets, system components,

and distributed devices with the largest possible cross-section (at least 16 mm²).

● Ground unused lines at one end in the cabinet.

● Choose the greatest possible clearance between the power and signal cables (at least 20 cm). The greater the distance over which the cables are routed in parallel, the greater the clearance must be. You must install additional shields if sufficient clearance cannot be maintained.

● Avoid unnecessarily long cable loops.

● Surge suppressors – e.g. RC elements or varistors – must be connected to the solenoids of contactors and relays in the device.

● In order to reduce noise/interference entering or exiting via the cable, filter auxiliary voltages in the control cabinet.

6.4 Potential conceptA noise-free connection between the internal and external supply voltage can be achieved by connecting the 0 V potentials to each other and grounding them. This also eliminates the need for the control circuit insulation monitor required by DIN EN 60204-1.

Figure 6-3 Potential concept

6.5 Connecting equipotential-bonding conductorsAll cabinets belonging to the system are connected by signal cables. Also connect the cabinets using equipotential-bonding conductors; according to the following diagram, for example:

Figure 6-4 Equipotential bonding conductor

Electrical connection6.5 Connecting equipotential-bonding conductors


Malfunction as a result of a missing equipotential-bonding conductorIf the control cabinets are not connected to an equipotential-bonding conductor, malfunctions can occur in the converter.

● Connect all control cabinets involved in meshed drives to an equipotential-bonding conductor (min. 16 mm2). The PE connection provided by the customer is not sufficient.

6.6 Using the equipotential bonding strip and shield busEach cabinet is equipped with an equipotential bonding or grounding bar to make it simpler to connect equipotential bonding conductors.

Connect all internal and external components to this equipotential bonding busbar. is Attach the shields of incoming and outgoing cables directly to the shield bus. It is important here to establish the greatest possible area of contact and a good conductive connection.

Figure 6-5 Equipotential bonding strip

6.7 Connecting the protective groundingConnect the protective grounding to the cabinets and components in the system via the PE conductor. Use the ground clamps for this, or the special terminal provided for the auxiliary voltage.

Route the protective conductors in accordance with IEC 60204‑1 (DIN EN 60204‑1/VDE 0113 Part 1) Safety of machinery – Electrical equipment of machines – Part 1: General requirements.

Where possible, also connect the cabinet conductively over a large area with the building ground.

Note

The equipotential bonding conductor does not have the function of a protective conductor. The equipotential-bonding conductor is required for safe operation and as an interference suppression measure.

Electrical connection6.7 Connecting the protective grounding


6.8 Laying the signal linesMalfunction due to common cable installationMalfunctions can occur in the converter if cables with differing voltage levels are laid together with internal cables in one cable duct in the cabinet.

● Do not run cables coming from the outside, for example to the terminal strips, together with internal cables in one cable duct.

Ensure that the following instructions are complied with:

● All signal lines must be shielded. The cable shield should be braided, because cables shielded by tape or foil are five times less efficiently protected against interference. Always ground the cable shields at both ends. Contacting at one end is advantageous in exceptional cases only.

● Clamp the shield of incoming analog and binary cables to the shield busbar at the entry point into the cabinet. Continue running the cable, still shielded, to the terminal strip or board. No shields are connected to the terminal strips or boards.

● Serial connecting cables must be shielded. Place the shield on the metallic connector housing. Also connect the shield to the shield rail. Do not connect the cable shield to a ground pin of the connector.

● The connector housing and front plate of the boards do not provide adequate cable shielding. Connect the cable shields at both ends to the shield rails in the cabinets. Always use shielded analog signal cables, regardless of whether they are installed inside or outside cabinets. In order to increase the effectiveness of the shielding, ground spare conductors at both ends.

6.9 Laying the cable shieldsIn the case of analog signal lines carrying small signals (mV or µA), attach the cable shield to the shield bus in the cabinet at one end. In this way you avoid ground loops and line-frequency interference. You can also connect the open shield end to the enclosure via a radio interference suppression capacitor (e.g. 0.1 µF 100 V MKT).

6.10 Separating adjacent cabinets using unsuppressed contactorsDo not use any contactors without suppression in the converter cabinets or in cabinets that are connected to the converter cabinets. All contactors installed in the factory are already equipped with a suppression circuit. If you use unsuppressed contactors in an adjacent cabinet, you must partition off the cabinets using a lateral metal plate.

Connect surge suppressors to contactor solenoids that are connected to the same line supply as the auxiliary power supply of the converter – or are located near the converter (e.g. RC elements, varistors).

Electrical connection6.10 Separating adjacent cabinets using unsuppressed contactors


6.11 Laying additional wiringKeep any additional wiring in the cabinet as short as possible. Route the additional wiring tightly against the cabinet enclosure or the mounting plates. You must twist unshielded cables belonging to the same circuit (outgoing and return conductors).

See alsoElectromagnetic compatibility (Page 81)

6.12 Connecting the power unit

6.12.1 Connecting power cables

PreconditionsYou may connect the cable shields only to the transformer or the motor (away from the converter).

① Circuit breaker ✓ Connect shield② Line-side transformer X Do not connect shield③ Converter ④ Machine-side transformer ⑤ Motor

Figure 6-6 Shield support

Separately route back additional equipotential bonding conductors to the converter. The cross section of this conductor must be at least as large as the total cross section of the shields.

Figure 6-7 Example: Equipotential bonding conductor

Electrical connection6.12 Connecting the power unit


Detailed information about cabling of the converter is provided in the circuit diagrams supplied.

● Please ensure that the maximum cable lengths between the converter and motor are not exceeded.

● Make sure that the permissible cable capacitance is not exceeded.

● Use appropriate screws for the cable lugs provided.

● The tightening torque for the M12 screws is 50 Nm.

● Clean the contact surfaces before screwing the connections.

● Apply a thin layer of grease to the screws.

Table 6-1 Cleaning agents and grease

Materials requiredCleaning agent Ethyl alcoholGrease 2G from Elektrolube

Procedure1. Cut out the floor panel for the power cables. When doing this observe the information in the

dimension drawing.

NOTICE

Damage caused by electrical flashovers and arcing

Chips are created when cutting out the floor panel. Chips in the converter shorten clearances and creepage distances and can lead to flashovers.● Cut out the floor panel outside the area of the converter.● Take care that no metal chips are left in the converter.● Protect cut edges to prevent damage to the cable insulation.

2. Make the connection between the supply and the converter and between the converter and the motor with the required number of parallel power cables.

3. Insert the power cables into the power unit from below, upwards through the hole in the baseplate.Anchor bars are provided for strain relief. On the system side, only use clamps that are suitable for the short circuits that could potentially occur.

4. Fix cable sealing ends to the power cables.

5. Connect the shields of shielded cables to ground on the transformer or the motor. Do not connect the power cable shields at the converter side.



6. Fix the power cables from behind to the front. The connection busbars are labeled with the phase designation.

7. Seal the floor panel and the cables passing through the panel so that they are air-tight.

NOTICE

Damage caused by overheating

Unless the floor panel is air-tight, adequate cooling cannot be guaranteed. As a consequence, converter components overheat.● Seal any access holes made in the floor panel immediately after installation so that they

are air tight, in order to ensure sufficient cooling.

6.12.2 Connecting the signal cablesThere are terminal strips and interfaces on the Power Stack Adapter in the electronics compartment of the power unit. The signal traffic to the open-loop and closed-loop control cabinet is handled via these interchange points.

The terminal blocks are used to wire up the following:

● Signals

● Auxiliary voltage for fans and anti-condensation heating systems

● Power supply for the electronics

ProcedureTo connect the signal lines, proceed as follows:

1. Connect the signal lines at the intended clamping points.

2. Connect the shield to the shield bus as shown under Using the equipotential bonding strip and shield bus (Page 85). Refer to the "Circuit manual for power unit" for the precise assignment. Pay attention to the EMC directives.



6.13 Connecting the closed-loop control

6.13.1 Connecting ground

DANGER

Danger due to failure of the protective and monitoring equipment

The converter must be grounded to ensure that it operates safely and reliably. If the converter is operated with insufficient grounding, then the protection and monitoring functions can fail.

Death, serious injury, or material damage will result.● Always apply all of the necessary protective measures.● Always observe the five safety rules when working with the converter.● Follow these steps when grounding the machine:

– Establish the connections in a cabinet.– Ensure that the connections are also established over several cabinets.– Establish the ground connection for the whole plant immediately.

Each cabinet has a grounding lug for grounding the components installed in the cabinet. It is located at the bottom of the cabinet. Connect the cabinets securely to the plant grounding system via these grounding lugs.

Figure 6-8 Grounding lug

6.13.2 Connecting the auxiliary voltageConnect the auxiliary voltage (e.g. for SITOP) to the terminal block. The maximum cross-section of the cables is 2.5 mm2. You will find detailed information in the terminal diagram or in the circuit manual under "Technical specifications and drawings".

See alsoTechnical specifications and drawings (Page 145)

Electrical connection6.13 Connecting the closed-loop control


6.13.3 Connecting circuit breakers

To connect the circuit breaker, proceed as follows:

1. Disconnect the cabinet from the power supply.

2. Route the control cables into the cabinet from below.

3. Connect the shields of the control cables to the serrated bar. For additional information, see Chapter "Using the equipotential bonding strip and shield bus (Page 85)".

4. Connect the control cables as specified in the circuit manual.

6.13.4 Connecting the encoder

Procedure

NOTICE

Damage caused by incorrectly connected external encoder

Components can be damaged if the external encoder is not connected or operated correctly.● Only one measuring system can be connected to each sensor module. The sensor module

is wired internally to the customer terminal strip. For further information, see the circuit manual.

To connect the encoder, proceed as follows:

1. The five safety rules must be observed.

2. Disconnect the cabinet from the power supply.

3. Route the cables from the encoder into the cabinet from below.

4. Route the cable further up into the cabinet until it reaches the customer terminal strips.

5. Connect the signal line to the customer terminal strip. You will find details of this in the circuit manual.

6. Connect the shield of the encoder cable directly to the shielding bus (serrated bar). It is important here to establish the greatest possible area of contact and a good conductive connection. Use metal ground clamps to secure the shield in place.



Connection example: HTL encoder, bipolar, with reference signalThis example shows the connection assignment on the sensor module. The terminals of the sensor module are wired to the customer terminal strip. For further information, see the circuit manual.

Figure 6-9 Connection example: HTL encoder, bipolar, with reference signal

Use a bipolar connection. The unipolar connection should only be employed when the encoder type being used does not provide push-pull signals.

See alsoThe 5 safety rules (Page 15)

6.13.5 Connecting the external safety loopYou can extend the "Safety shutdown" function using external devices. For instance, using an Emergency Stop pushbutton or isolated contacts from the excitation. This is the reason that the contacts of the safety circuit are connected to terminals. Precise data on these terminals is provided in the circuit diagram and terminal diagram.

WARNING

Danger due to high voltages





ProcedureTo connect the external safety loop, proceed as follows:

1. Switch off the converter.

2. Remove the jumper over the terminals, inserted in the factory, that you wish to use.

3. Connect the external safety circuit to these terminals.

6.14 Interconnecting optional connectionsDepending on the range of options installed, further connections have to be interconnected. Detailed information about interconnecting these options with the interfaces is provided in the circuit manual.

6.15 Fastening the cable ducts with cable tiesFasten all cable ducts whose cover faces downward with cable ties. Wind the cable ties around the entire cable duct. The cable ties must be located at the same positions as in the delivered state.

Figure 6-10 Schematic diagram: Fastening the cable ties

Electrical connection6.15 Fastening the cable ducts with cable ties


Electrical connection6.15 Fastening the cable ducts with cable ties


Commissioning 7When carrying out any work, carefully observe the information provided in Chapter "Safety instructions (Page 15)".

NOTICE

Material damage caused by transport indicators remaining in the device during operation

In operation, as a result of high temperatures, the transport indicators can become detached and fall into the device. This can result in material damage.● Remove the transport indicators before commissioning. Remove any adhesive residue

from the transport indicators using methylated spirits.

Detailed information on commissioning and operating the device is provided in the Commissioning Manual that addresses commissioning engineers.

WARNING

Incorrect commissioning

Malfunctions can occur as a result of incorrect commissioning and parameterization. This can result in premature failure and subsequent damage to the drive system. This can result in death, serious injury or material damage. Incorrectly performed commissioning can result in the warranty becoming null and void.

It is not permissible to commission the device if it is dirty. Immediately contact Customer Support. You can find the relevant contact person under "Service & Support".

This device may only be commissioned by electrically skilled persons who have been adequately trained on this product, and have experience with commissioning this product and the associated plant and system components. The electrical technician commissioning the equipment must be trained on the specific product as a result of the differences between the individual products, e.g. regarding topology and closed-loop control.

Obtain information about the range of SITRAIN training courses available through your local contact person. Make use of the support and services offered by the responsible Siemens Service Center when commissioning this equipment. You can find the relevant contact person under "Service & Support".


Commissioning


Operation 88.1 Safety instructions for operation


Danger due to high voltagesHigh voltages are present during operation and also after the device has been switched off. When touched, these voltages can lead to death or severe injury.

● Ensure that no voltage is present when the doors of the power unit are open.

● Keep the doors closed when operational.

Danger due to high voltages of the demagnetizing equipmentThe demagnetizing equipment can supply the complete converter system such as motor, transformer, drive, and circuit breakers with high voltage. Coming into contact with this high-voltage can result in death or serious injury.

● Always carefully observe the safety instructions on the product as well as the five safety rules.

Danger if operated in spite of faultsOperation with an active fault can result in death, severe injury and significant material damage.

● Observe the fault and alarm messages.

● Eliminate the source of the fault. Only then commission the device. You can find further information on alarms and faults in the section "Indicating and rectifying faults."

● If it is not possible to correct a fault, inform the manufacturer's service personnel immediately. For additional information, see Chapter "Service & support".

Danger when operating with ground faultThe type and location of the fault cannot be established just from a ground fault error message. For example, the glow discharge at the winding overhang of the machine may result in a fault signal. In the event of continued operation, serious aftereffects all the way to electric arcs are possible. This can result in death, serious injury or material damage.

● Immediately switch off the device if a ground fault occurs during operation. Then identify and eliminate the source of the ground fault.

● The company operating the plant or system is responsible for the consequences when the device is still operated after a ground fault has been identified. Carry out a risk analysis.


Danger when the permissible short-circuit currents are exceededSerious follow-on faults are possible, if the specified short-circuit current values are exceeded. This can result in death, serious injury or material damage.

● Observe the maximum permitted short-circuit currents and maximum specified short-circuit times.

Damage caused by incorrect parameter assignmentMalfunctions can occur if you change parameters.

● Do not change the parameters, e.g. for the motor circuit-breaker.

Note

To complement these operating instructions, the List Manual contains an overview of all parameters as well as a selection of function diagrams to describe the operating principle.

8.2 Parameters

The drive is adapted to the relevant drive task by means of parameters. Each parameter is identified by a unique parameter number and specific attributes. Such attributes are, for example:

● Readable attributes

● Writable attributes

● BICO attributes

The parameters can be accessed via the following means:

● PC with commissioning tool via PROFIBUS

● Operator panel

Parameter types The following parameters are available:

● Adjustable parameters (write/read)Adjustable parameters directly influence the response of a function, e.g. the ramp-up and ramp-down time of a ramp-function generator.

Operation8.2 Parameters


● Visualization parameters (read-only)Display parameters are used to display internal variables, e.g. the actual motor current.

Figure 8-1 Parameter types

All these drive parameters can be read and changed via PROFIBUS using the mechanisms defined in the PROFIdrive profile.

Parameter categories The parameters for the individual drive objects (DO) are categorized according to data sets as follows:

● Data-set-independent parametersThese parameters exist only once per drive object.

● Data-set-dependent parametersThese parameters can exist several times for each drive object and are addressed via the parameter index for reading and writing. The following data set types can be distinguished:

– CDS: Command data setBy parameterizing several command data sets and switching between them, the drive can be operated with different preconfigured signal sources.

– DDS: Drive data setThe drive data set contains the parameters required for switching the drive control parameters.The CDS and DDS data sets can be switched during operation. Further data set types also exist, however these can only be activated indirectly by means of a DDS changeover.

– EDS: Encoder data set

– MDS: Motor data set

8.3 Setpoint channel and closed-loop control

8.3.1 Setpoint additionFine tuning (correction variable) often needs to be carried out on site for applications in which the command variables are generated by central control systems.

Operation8.3 Setpoint channel and closed-loop control


This can be carried out using the addition point for the main and additional setpoint in the setpoint channel. Both variables are imported simultaneously via two separate or one setpoint source and added in the setpoint channel.

8.3.2 Direction of rotation changeoverYou have the following options of subsequently inverting the phase sequence:

● Replace the motor cable.

● Enter a negative setpoint or change the device parameterization.

Direction of rotation changeover is initiated as follows:

● For control via PROFIBUS using control word 1, bit 11

● For control via the cabinet operator panel (LOCAL mode) using the "Reverse direction of rotation" button

Note

Only one direction of rotation is enabled in the factory setting.

8.3.3 Suppression bandwidthsVariable-speed drives can generate critical whirling speeds within the control range of the entire drive train. This prevents steady-state operation in their proximity, that is, although the drive can pass through this range, it must not remain within it because resonant oscillations may be excited.

The suppression bandwidths allow this range to be blocked for steady-state operation. Because the points at which critical whirling speeds occur in a drive train can vary depending on age or thermal factors, a broader control range should be blocked.

To ensure that the speed does not constantly increase and decrease in the suppression bandwidth (speeds), the bands are assigned a hysteresis.

Specify a minimum speed in order to block a specific range around the stopped state for stationary operation.

8.3.4 Speed limitationSpeed limitation can limit the maximum permissible speed of the entire drive train to protect the drive and load machine/process against damage caused by excessive speeds.



8.3.5 Ramp-function generatorThe ramp-function generator limits the rate at which the setpoint changes when the drive is accelerating or decelerating. This prevents excessive setpoint step changes from damaging the drive train. Two ramp function generators are available; these can be selected using parameters.

To improve the control properties with regard to load surges, set additional rounding times in the lower and upper speed range.

Setting rounding times has the following advantages:

● It protects mechanical components, such as shafts and couplings.

● It prevents the actual speed value from being overshot when the setpoint is approached, thereby improving control quality.

The ramp-up and ramp-down times each refer to the maximum speed.

Note

If rounding times are too long, this can cause the setpoint to be overshot if the setpoint is reduced abruptly during ramp-up.

Rounding is also effective in the zero crossover; When the direction of rotation is reversed, the ramp-function generator output is reduced to zero via the initial rounding, the ramp-down time and the final rounding. Then, the newly inverted setpoint will be approached via the initial rounding, the ramp-up time and the final rounding.

Rounding times that can be set separately are active in the event of a fast stop (OFF3). The actual ramp-up/ramp-down times increase with active rounding.

8.3.6 Vector controlVector control has the following advantages:

● Stability vis-à-vis load and setpoint changes

● Short rise times for setpoint changes to facilitate an improved control response

● Short settling times for load changes to facilitate an improved response to disturbances

● Acceleration and braking are possible with the maximum available torque.

● Motor protection due to variable torque limitation in motor and regenerative mode

● Drive and braking torque controlled independently of the speed

These benefits can even be achieved without speed feedback.

You can use vector control with or without an encoder. A speed encoder is only required in the following cases:

● Maximum speed accuracy is required.

● The most stringent demands on the dynamic response are required.

● Better command behavior is desired.



● The shortest possible settling times during disturbances are required.

● Prolonged operation at speeds of less than 10% is necessary.

● A high starting torque for approach is required if, for example, 5% of the speed is not achieved in 10 s.

8.4 Monitoring and protection functions

8.4.1 Safety shutdown of the converter

Tripping of the circuit-breaker in case of undervoltageIn the event of a serious fault, the converter is rapidly switched into a de-energized state by the safety shutdown function.

The circuit-breaker must be equipped with an undervoltage trip to ensure the wire-break protection for the circuit-breaker OFF command.

If a circuit-breaker OFF command is issued as a result of an overvoltage trip, the circuit-breaker is switched off so that it is fail safe.

WARNING

Danger due to high voltages after a safety shutdown



8.4.2 Speed monitoring with incremental encoderPermanent speed monitoring enables motor control without an encoder. If higher-performance applications require permanent speed monitoring, additional incremental encoders can be connected to options A51 - A54. Higher-performance applications include, for example, closed-loop position control or prolonged applications involving low speeds.

Operation8.4 Monitoring and protection functions


8.4.3 Uncontrolled stop, EMERGENCY STOP category 0

FunctionThis function concerns the stop category 0 EMERGENCY STOP for an uncontrolled stop in accordance with EN 60 204-1. The function enables the voltage to be isolated via the circuit breaker. The motor coasts down.

The safety shutdown is based on a single circuit. Protection against wire breakage is assured due to the use of circuit breakers with undervoltage release. The emergency stop button used is forced.

The following markings have the function:

● Use of proven components

● Suitable for the intended use

● The occurrence of a fault can result in the loss of the safety function.

The probability of a fault occurring is reduced as far as possible by the use of forced contacts. The use of a single circuit in conjunction with undervoltage release achieves compliance with safety category 1 to EN 954-1.

Note

This has not been officially certified in Germany.

ConnectingFirstly, the contacts of the EMERGENCY STOP button are integrated into the circuit breaker control circuit. Secondly, the remaining NC contact is connected to the terminal block.

EMERGENCY STOP button Where connected=.DB-S1001:31-32 EMERGENCY STOP customer =.DB-X05:9, 10

Max. connectable cross-section: 4 mm² (AWG 10)

Activation of the circuit breakers is described in the section entitled "Connecting the circuit breakers".

Operation8.4 Monitoring and protection functions


8.4.4 Protection function of ground fault detectionThe entire power unit is isolated. An insulation fault alone will not normally impair operation. However, in the event of such a fault, the voltage of the other two phases increases with respect to ground. In the medium term, this rise in voltage can result in damage. An additional error can cause a short-circuit.

WARNING

Danger when operating with ground fault

The type and location of the fault cannot be established just from a ground fault error message. For example, the glow discharge in the machine's coil end may be the cause of the fault message. In the event of continued operation, serious aftereffects (all the way up to electric arcs) are possible. This can result in death, serious injury or material damage.● If a ground fault is experienced during converter operation, the converter must be switched

off immediately. Then identify and eliminate the source of the ground fault.● The plant operating company is responsible for the consequences, if the converter is still

operated after a ground fault has been detected. Carry out a risk analysis.

8.5 Fault and system messages

Hardware traceThe drive saves data to the CompactFlash card each time there is a fault trip. Customer Supports requires this data in the case of a fault.

Save your data as follows:

1. Switch off the drive.

2. Switch off the power supply for the control cabinet. Remove the CompactFlash card from the Control Unit.

3. Save all data of directory "Install\Sinamics\Trace".

4. Send these data to Customer Support.

8.5.1 External warnings and faultsWith the terminal blocks TM15/TM31, there are 24 terminals. With STARTER or SCOUT, you can select which predefined messages are displayed and which protection devices are to be triggered. The list of parameterized faults and alarms can be found in the List Manual in the "Faults and alarms" section.

Operation8.5 Fault and system messages


8.5.2 Diagnostics

8.5.2.1 Diagnostics via LEDs

LEDs of the open-loop and closed-loop control cabinet

Table 8-1 Meaning of indicator lights

Indicator light Action MeaningH21 White Continuous light The converter is in operation. The circuit breakers are

switched on and the converter pulses are enabled.White Flashing light ● The converter is starting up. The auxiliaries are

switched on and the circuit breakers are closed.● The auxiliary circuits and the circuit breakers are

switched on, the converter pulses are disabled.● Shutdown cycle OFF1, OFF2 or OFF3 is running.● The demagnetization equipment is in operation (only in

the case of starting converters).Test mode is selected.

H22 Green Continuous light The converter is ready to start. All circuit breakers are switched off. OFF2 or OFF3 are not active.

Green Flashing light All circuit breakers are switched off. The converter is, how‐ever, not ready to start. An OFF2/OFF3 or a fault is active.

H23 Yellow Flashing / contin‐uous light

Warning

H24 Red Flashing / contin‐uous light

Fault

If a fault or an alarm becomes active, the lamp flashes for 5 seconds. It then switches to the continuous light state. If a new message is occurs while the lamp is continuously lit, the lamp begins to flash again for 5 seconds and then is again continuously lit. The lamp is extinguished once the cause of the problem has been resolved.

LEDs of the Sirius safety relay

Table 8-2 LEDs of the Sirius safety relay

LED OperationPOWER CHANNEL1 CHANNEL2 Line supply EMERGENCY

STOPON Release circuits

☀ ☀ ☀ On Not actuated Actuated Closed☀ ○ ○ Actuated Not actuated Open☀ ○ ○ Not actuated Not actuated Open Fault



LED OperationPOWER CHANNEL1 CHANNEL2 Line supply EMERGENCY

STOPON Release circuits

☀ ○ ○ ● Relay jammed ● Motor contactor jammed● Defect in electronics

Open

○ ○ ○ Cross-circuit/ground fault in EMERGENCY STOP circuit/no supply voltage

LEDs of the Power Stack Adapters

Table 8-3 LEDs of the Power Stack Adapters

LED Color Status Description; cause RemedyPWR - Off 24 V power supply has failed or is too low

(< 14 V) or internal fuse defective.Check input voltage.If input voltage is > 18 V and LED off: Return component for repair.

Red Continuous light

24 V power supply is available (>14 V); internal board voltage fault.

Check input voltage.If input voltage is > 18 V and LED red: Return component for repair.

Green Continuous light

24 V power supply OK.Internal board voltages OK.

--

RUN / ERR

- Off The electronic power supply is missing or lies outside the permissible tolerance range.

-

Green Continuous light

The component is ready for operation and cyclic DRIVE-CLiQ communication is in progress.

-

Orange Continuous light

DRIVE-CLiQ communication is being es‐tablished.

-

Red Continuous light

At least one fault is present in the com‐ponent.LED is controlled irrespective of the cor‐responding messages being reconfig‐ured.

Remedy and acknowledge fault.

Green/red 0.5 Hz flashing light

Firmware download in progress. -

2 Hz flashing light

Firmware download is complete. Waiting for POWER ON.

Carry out a POWER ON.

Green/orangeor Red/orange

Flashing light Component recognition via LED is acti‐vated.The color depends on the LED state when component recognition is activated.

-



8.5.2.2 Diagnostics via parameters

Diagnostic parameters for the device statusSee the List Manual for a description of the individual parameters.

r0002 Drive status DODisplay of drive status VEKTORGL

r0046 Missing enable signal DODisplays missing enable signals that are preventing the servo drive control from being commissioned.

VEKTORGL

r0050 Active command data set (CDS) DO Displays the active command data set (CDS). VEKTORGLThe command data set selected via binector inputs p0810, p0811, p0812 and p0813 is displayed via r0836. For more information about binector inputs, see the List Manual.

Diagnostic parameters for digital inputs/outputs, PSA inputs/outputs

r0721 CU digital inputs, terminal actual value ModuleDisplays the actual value at the digital inputs Control UnitIf a DI/DO is parameterized as output (p0728.x = 1), then r0721.x = 0 is displayed.

r0747 CU, digital outputs status ModuleDisplays the status of digital outputs Control UnitInversion via p0748 is taken into account. It does not matter whether DI/DO is set as an input or output (p0728).

r4022 Status of digital inputs on TM31 ModuleDisplays the status of the digital inputs of Terminal Module 31 (TM31). TM31

r4047 Status of digital outputs on TM31 ModuleDisplays the status of the digital outputs of Terminal Module 31 (TM31) TM31Inversion via p4048 is taken into account.It does not matter whether DI/DO is set as an input or output (p4028).

r4022 Status of digital inputs on TM15 ModuleDisplays the status of the digital inputs of Terminal Module 15 (TM15). TM15



r4047 Status of digital outputs on TM15 ModuleDisplays the status of the digital outputs of Terminal Module 15 (TM15). TM15It does not matter whether DI/DO is set as an input or output (p4028).

R6580 Status of the Power Stack Adapter inputs/outputs DODisplays the status of the Power Stack Adapter inputs/outputs VEKTORGL

Diagnostic parameters for the motor sequencer

r6260 Motor sequencer control commands DODisplays the motor sequencer control commands VEKTORGL

Diagnostics parameters for the drive status

r0899 Drive object status word DODisplays the status word of drive object 1 (Control Unit). CU_GL

r6222 Status word sequencer DODisplays the GL status word VEKTORGL

r6261 Status word motor sequencer DODisplays the GL motor sequencer VEKTORGL

Diagnostics parameters of fault and alarm buffers:

r0945 Fault code DODisplays the numbers of faults that have occurred All objects

r0946 Fault code list DOLists the fault codes stored in the drive unit All objects

r0947 Fault number DODisplays the numbers of faults that have occurred All objects

r0948 Fault time received in milliseconds DODisplays the system runtime in milliseconds when the fault occurred. All objects



r0949 Fault value DODisplays additional information about the fault that occurred (as integer number). All objects

r2122 Counter, alarm buffer changes DOThis counter is incremented every time the alarm buffer changes. All objects

r2123 Alarm time received in milliseconds DODisplays the system runtime in milliseconds when the alarm occurred. All objects

r2124 Alarm value DODisplays additional information about the active alarm (as integer number). All objects

r2125 Alarm time removed in milliseconds DODisplays the system runtime in milliseconds when the alarm was cleared All objects

8.5.2.3 Indicating and rectifying faultsThe cabinet device has a number of protective functions that protect the converter from damage in the event of a fault (faults and alarms).

A list of faults and alarms with remedies for their rectification can be found in the List Manual in the "faults and alarms" chapter.



Maintenance 99.1 Safety instructions for maintenance


Danger due to improper maintenance and repairsImproper repairs can result in death and serious physical injury.

● Only qualified maintenance and installation personnel may perform repairs.



Danger as a result of high voltages from external supplies Magnetizing and demagnetizing equipment that is fed from an external voltage source can result in high voltages. This voltage can result in death or serious injury.

● Ensure that no voltage from external feeds exists before commencing maintenance and repair work.

Danger due to high voltages of the snubber circuit capacitorsThe snubber circuit capacitors are not equipped with discharge resistors. If the connection to the capacitor is interrupted, high voltages of up to several 1000 V can result, and cause an electric shock.

This can result in death, severe injuries and significant material damage.

● You must always handle the capacitors as if they are charged.

● Discharge the snubber circuit capacitors.

● Short-circuit the snubber circuit capacitors before commencing any work.


Danger due to high voltages at the anti-condensation heatingThe anti-condensation heating system is used when the device is switched off during non-operational periods or when maintenance work is being carried out. For this reason, the heating is supplied with voltage from a separate line supply. When the power supply voltage for the anti-condensation heating is connected – also for an EMERGENCY OFF or when the main switch is open – a hazardous voltage is still present. This voltage can cause serious injury.

● The five safety rules must be observed.

Risk of burns due to hot anti-condensation heating surfaceWhen 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.

Injury when fallingWhen climbing onto the cover of the anti-condensation heating there is a risk of injury.

● Therefore, do not use the anti-condensation heating system to help you get to the top of the cabinet.

Damage due to non-authorized spare partsUsing non-approved spare parts can affect the function of the equipment and damage it. Third-party spare parts and unapproved spare parts may not meet the requirements.

● Only use spare parts that have been approved by the manufacturer.

Damage caused by foreign bodies in the deviceIf foreign bodies are left in the device after installation and maintenance work, this can cause damage when the device is switched on.

● Before switching on, carefully check that there are no foreign objects that have been left behind. Remove any foreign bodies.

Damage due to contamination and dirtContamination and dirt can damage the device.

● Visually inspect the equipment at least once per year. For more information, please refer to the section "Visual inspections".

● Dust deposits inside the cabinet unit must be removed at regular intervals (or at least once a year) by qualified personnel in line with the relevant safety regulations.

Maintenance9.1 Safety instructions for maintenance


Note

The actual intervals at which maintenance procedures are to be performed depend on the environmental and operating conditions. Define maintenance intervals that reflect your plant-specific environmental and operating conditions and meet your availability requirements. When doing so, take the prescribed maintenance intervals into consideration, as well as the instructions for repairing and replacing installed components.

See alsoVisual inspections (Page 117)

Note

Siemens offers its customers support in the form of a service contract. For further details, contact your regional office or sales office.

Note

Inform the manufacturer about each maintenance job that has been carried out and about each spare part replacement for the purposes of a reliability analysis.

9.2 Grounding the system

WARNING

Danger due to high voltage after shutdown

High voltages can still be present even after shutdown. Touching the device can result in death or serious injury.● Only work on the power unit if it has been sufficiently grounded. Before touching the device,

carefully ensure that the following parts of the power unit are de-energized and are in a no-voltage condition:– Internal busbars– Input and output terminals– Auxiliary power supply

● Always observe the five safety rules (Page 15) when carrying out any work on the device.

Use a three-pole grounding harness for fixed ball points to ground the system. When ordering a grounding harness, contact Service & Support.

Use a sufficient number of grounding harnesses corresponding to the configuration. A grounding harness is required for each three-phase system.

Maintenance9.2 Grounding the system


The diagram shows the method of attaching the grounding spider. Secure the clamps for the grounding spider to the ball heads ② and ③ in the cabinet.

① Schematic diagram of ball head② Ball head③ Ball head

Figure 9-1 Schematic diagram for attaching the grounding spider

Disconnecting the demagnetization equipment from the low-voltage supplyFor systems with demagnetizing equipment, in addition to disconnecting the medium voltage, you must also disconnect the demagnetization equipment from the low-voltage supply.

DANGER

Electric shock hazard

To demagnetize, for example, the demagnetizing equipment generates a medium voltage from the 400 V supply and feeds this medium voltage into the system. When working on the system and with the fuse switch disconnector closed, if this voltage is touched, then it can result in death or severe physical injury.● Always open the fuse switch disconnector before working on the system. Observe the five

safety rules.

Maintenance9.2 Grounding the system


1. Swing open the fuse holder of the fuse switch disconnector.

2. Remove the fuse holder.

Figure 9-2 Fuse switch disconnector with fuse holder swung out

9.3 Opening the device

The drive is equipped with a door interlocking system. Depending on the design, this is an electromechanical door interlocking system or optionally a safety locking system.

The door of the closed-loop control cabinet is not electromechanically interlocked. For this reason, it can also be opened during operation.

The power unit doors can only be opened under the following conditions:

● The DC link current is zero.

● The firing pulses are disabled.

● Voltages at the input and output sides are below a minimum value.

● The circuit breakers are open.

● Any grounding switches that may be present are closed.

● The mushroom pushbutton on the control unit is actuated. By pressing the mushroom pushbutton, the contactor safety combination, and therefore the undervoltage protection to the power units, is interrupted. Secure the mushroom pushbutton so that it cannot be released by attaching a warning plate, for example.

Maintenance9.3 Opening the device


You can open the power unit door when the green "Door lock release" lamp is lit.

WARNING

Danger due to high voltages although the door interlocking has been released

Even when the door interlocking is released, dangerous high voltages can still be present at the auxiliary circuits (fans, anti-condensation heating, closed-loop control, etc.). High voltages can cause death or serious injury if safety rules are not observed or if equipment is handled improperly.● Make sure that work is only carried out by qualified personnel under due observance of the

five safety rules, the warning information in these operating instructions, and the safety-related information on the product itself.

If the auxiliary voltage fails, you can only unlock the doors manually. To unlock the doors, proceed as described in the chapter titled "Preparation for use".

See alsoOpening doors in preparation for use (Page 69)

9.4 Preventive maintenance

The purpose of an inspection is to ascertain and evaluate the current status of the equipment. An inspection mainly comprises visual checks. Inspections should be carried out based on a schedule that meets the needs of the special ambient conditions at the location of use. The following servicing and inspection instructions are used as the basis for regular inspection of the equipment.

Maintenance work Carried out by Frequency CommentsCheck the cooling system Operating

company After 30 000 operating hours

Check the fans

Clean the outside of the cabi‐net

Operating company

As required Visual inspection, clean if required

Clean the inside of the cabinet Siemens serv‐ice personnel

Annually Visual inspection, clean if required

Check power and control con‐nections

Operating company

After one year, and ev‐ery four years thereafter

Check internal connections Siemens serv‐ice personnel

After one year, and ev‐ery four years thereafter

Carry out an inspection and visual check

Siemens serv‐ice personnel

Annually See the specifications in the Operating Manual

Check the software Siemens serv‐ice personnel

After every parameter modification, and every five years thereafter

Maintenance9.4 Preventive maintenance


Maintenance work Carried out by Frequency CommentsCheck spare parts Siemens serv‐

ice personnelAnnually

Check options Siemens serv‐ice personnel

See the specifications in the Operating Manual

9.4.1 Visual inspections

9.4.1.1 Equipment for visual inspectionsYou require the following basic equipment to carry out the visual checks and maintenance work:

● Mirror

● Flashlight

● Torque wrench for tightening screws

NOTICE

Damage due to contamination and dirt

Contamination and dirt can damage the device.● Visually inspect the equipment at least once per year. For more information, please refer

to the section "Visual inspections".● Dust deposits inside the cabinet unit must be removed at regular intervals (or at least once

a year) by qualified personnel in line with the relevant safety regulations.

Note

The actual intervals at which maintenance procedures are to be performed depend on the environmental and operating conditions. Define maintenance intervals that reflect your plant-specific environmental and operating conditions and meet your availability requirements. When doing so, take the prescribed maintenance intervals into consideration, as well as the instructions for repairing and replacing installed components.

9.4.1.2 Checking the isolating clearances● Slight, dry, non-conducting contamination is permitted.

● Remove contamination caused by dust in conjunction with high humidity.

See alsoCleaning (Page 124)



9.4.1.3 Checking hoisting solenoids and security bolts● Check the hoisting solenoids and security bolts at regular intervals.

● Replace defective hoisting solenoids and security bolts before (re)commissioning.

9.4.1.4 Checking the plug connections.

Regularly check the plug connections to ensure they are seated correctly and the contacts are not corroded.

Note

The fiber-optic cables for the gating boards must be properly inserted in the connectors.

9.4.1.5 Checking the cable and screw terminals● Check the cable and screw terminals regularly to ensure that they are secure.

● Tighten the screws if necessary. When doing this, comply with the specified torques (Page 74).

● Check the cabling for defects.

● Replace any defective parts immediately.

9.4.1.6 Checking the thyristor electronics● Check the thyristor electronics for contamination. Carry out this inspection when you service

the valves.

● Check whether the components are showing signs of failure. Examples of failure symptoms:

– Irreparable damage

– Traces of smoke

– Scorching

● Check the circuit boards with regard to the following criteria:

– Interruptions

– Short-circuits

– Minimum clearances

– Traces of smoke

– Scorching




9.4.1.7 Checking the filter mats● Check the air filters in the cabinet doors for pollution.

● Clean the filter mats or replace them if the air flow is obstructed.


Replacing filter mats (Page 122)

9.5 Maintenance

9.5.1 Replacing a fan

NOTICE

Improper fan storage

Even if the fan is not used, the bearing grease ages. The utility of the fan can be impaired.

Rotate the fan at least once a year. Do not store the fan for longer than two years before commissioning.

CAUTION

Injury caused by rotating fan

If the converter is equipped with a temperature-controlled fan, the fan can run on even if the power section is switched off. You can be injured if you touch the fan.● Wait until the fan has shut down.

For reliable operation, the fans must also be fitted with a monitoring device. Replace the fan in good time to maintain the availability of the device.

Removing the fan1. Disconnect the equipment.

2. Switch off the motor protection switch.

3. Remove the mesh cover on the junction box side of the fan. To do this, remove the seven screws of the mesh cover.

4. Open the cover of the junction box and remove the fan cables.

Maintenance9.5 Maintenance


5. The fan is attached to the roof section using four nuts, which are located inside the fan. Remove the four nuts including the contact washers. If required, also remove the mesh cover on the other side.

6. Lift the fan up and out. Eyebolts can be fitted on top of the fan so that it can be lifted out more easily.

CAUTION

Injury due to a falling fan

The fans are very heavy (approx. 50 kg). If incorrectly handled, fans can fall and result in injury and material damage.● Take extra special care when lifting the fans.

Installing the fan1. Insert the new fan.

NOTICE

Damage caused by insufficient cooling

Cooling is only ensured if the fan is rotating in the correct direction. ● When you are inserting the new fan, make sure that it rotates in the correct direction.

The direction of rotation is shown by a small arrow on the enclosure.

2. Tighten the four nuts including the contact washers with a torque of 25 Nm.

3. Connect the fan cable according to the circuit diagram.

4. Close the cover of the junction box.

5. Attach the mesh cover. Tighten the screws with the specified torque.

– The torque for the countersunk head screws is 4.5 Nm.

– The torque for the hex screws is 10 Nm.

Removing the fanFollow the five safety rules before replacing the fans.

NOTICE

Damage caused by insufficient cooling

Cooling is only ensured if the fan is rotating in the correct direction.● When you are inserting the new fan, make sure that it rotates in the correct direction. The

direction of rotation is shown by a small arrow on the enclosure.



① Junction box② Screws of the front brackets③ Rear fixing screws

Figure 9-3 Replacing the fan

1. Open the cover of the junction box ① and remove the fan cables.

2. Remove the front M8 screws for the brackets ②.

3. Loosen the rear M8 fastening screws ③ for the fan.

4. Pull out the fan and remove it from the converter. Eyebolts can be fitted on top of the fan so that it can be lifted out of the converter more easily.

CAUTION

Injury due to a falling fan

The fans are very heavy (> 50 kg).

If incorrectly handled, fans can fall and result in injury and material damage.● Please take special care when removing the fans from the converter.

Installing the fan1. Insert the new fan.

2. Move the fan onto the rear screws ③. Align the fan.

3. Insert the front screws M8 ②. Tighten the screws with a torque of 13 Nm.

4. Tighten the rear screws M8 ③ (tightening torque: 13 Nm).



5. Connect the fan cable.

6. Close the cover of the junction box ①.

9.5.2 Replacing filter mats

To prevent dangerous dust deposits from accumulating in the power unit components, additional filter mats are attached to the outside of the device.

The device must not be operated when the filter mats are dirty. Dirty filter mats can cause a premature thermal shutdown of the drive.

NOTICE

Damage due to dust deposits

Dust can enter the interior of the cabinet during filter mat replacement due to the suction of the running cabinet fans. Dust deposits can damage the device.● Ensure that no dust enters the cabinet when replacing the filter mats.

1. Remove the screws for the louvered fan grid in the cabinet door.

Figure 9-4 Example diagram: Replacing filter mats

2. Remove the filter mat.

3. If there is a slight amount of dirt, clean the filter mat at a suitable location. Depending on the degree of pollution, you can also clean the filter mats using a vacuum cleaner. If the filter mat is damaged, or the frequency of alarms increases, dispose of the dirty filter mat in the correct fashion. Use a new filter mat.

4. Insert the filter mat in the frame of the fan opening. In order that dirt is not drawn in, insert a clean mat in the same direction as it was installed before the cleaning.

5. Carefully place the louvered cover over the frame.

6. Retighten the cover screws.



9.5.3 Replacing the back-up battery of the AOP30 operator panel

Table 9-1 Technical specifications of the backup battery

Type CR2032 3V lithium batteryManufacturer Maxell, Sony, PanasonicNominal capacity 220 mAhMaximum permissible charging current 10 mA, limited to < 2 mA in the operator panelSelf-discharge at 20° C 1%/yearService life in the backup mode > 1 year at 70° C; >1.5 years at 20° CService life in operation > 2 years

Replacing the backup battery1. Switch off the main circuit-breaker.

2. Open the cabinet.

3. Disconnect the 24 VDC power supply and communications line on the operator panel.

4. Open the cover of the battery compartment.

5. Remove the old battery.

6. Insert a new battery.

7. Close the cover of the battery compartment.

8. Reconnect the 24 VDC power supply and communications line.

9. Close the cabinet.

Note

To ensure that no data is lost during a battery replacement, it must be replaced within one minute.

If the time is exceeded, the AOP settings and input screen texts are reloaded from the CompactFlash card by a restart of the AOP with a connection to the drive.

Set the clock to the new time.

Figure 9-5 Replacing the backup battery



Note

Dispose of the battery in accordance with the applicable country-specific laws and regulations.

Set date and time1. Using the "MENU" key, select the main menu of the AOP 30.

2. Using "F2", select the menu item "Commissioning/service". Confirm with "F5"

3. Using "F2", select the menu item "AOP30 settings". Confirm with "F5"

4. Using "F2", select the menu item "Set date/time". Confirm with "F5". Using "F2", select the appropriate input location for date or time. Enter the actual value using the numerical keys.

5. Use "F5" to save the settings.

9.6 Cleaning

NOTICE

Damage caused by aggressive cleaning agents

Aggressive chemical agents can damage the electronics. This can result in malfunction. Never use any type of chemical agent or liquid. ● Only remove severe dirt and contamination after prior consultation with service experts for

the particular product.

Use a dry, clean, lint-free ESD cleaning cloth. Wipe all external parts of the rack with it. Make sure that the dirt is not distributed, but actually removed by constant changes of the wiping surface of the cloth. For significant levels of pollution and dirt, use an ESD cloth soaked in ethyl alcohol (however, not so much that it drips from the cloth).

Maintenance9.6 Cleaning


9.6.1 Cleaning aluminum partsThe surface of untreated aluminum is always covered by a thin but dense oxide skin. This natural oxide layer acts as surface protection and is the reason for the good weathering resistance of aluminum materials. In most cases, this means that additional protective measures are superfluous.

● Remove greasy layers using ethyl alcohol.

● If there are other very dirty areas, use ESD-compliant fiber or plastic brushes for cleaning.

NOTICE

Damage caused by unsuitable cleaning agents and cleaning utensils

Using unsuitable cleaning chemical agents and cleaning instruments may transfer metallic, corrosion-inducing impurities onto the aluminum. This can result in corrosion damage.● Only use cleaning agents that are suitable for aluminum.● Use ESD-compliant brushes and cloths.● Do not use cleaning cloths and brushes that have been treated with copper, brass,

bronze or other heavy metals. ● Use neither brass, bronze, or steel-wire brushes nor cloths or steel wool interwoven

with copper wire.

9.7 Repairs

WARNING

Burns caused by inadequate cable insulation

Improperly laid or damaged cables and incorrectly attached cable shieldings can heat up in places and cause fires or short-circuits wherever they make contact.● Check whether all the cable shields are intact.● Insulate damaged cable shields.● Make sure that a short-circuit cannot occur on the power cables due to failure of the

insulation as a result of incorrect cable installation.

NOTICE

Damage if the auxiliary power supply is not available

When the auxiliary power supply is switched off, data about error message statuses can be lost. Inadequate diagnostic and error rectification measures can result in material damage.● We recommend using an uninterruptible power supply (UPS). If you are unsure of the

measures necessary after the device fails, or if a fault cannot be rectified, contact the Service Center.

Maintenance9.7 Repairs


After performing repairs, refasten all cable ducts whose cover faces downward with a cable tie. The cable ties must be located at the same positions as in the delivered state. You will find more information in "Fastening the cable ducts with cable ties (Page 93)".

NOTICE

Damage caused by an incomplete repair

In the case of damage, several components can have a fault condition. Consequential damage can occur if the device is recommissioned but the repair work carried out was not complete. ● Check whether secondary faults have occurred on components which have failed.

Replace the components involved.

Measures in the event of an errorIt is not possible to fully test repairs that are carried out on site. Return the defective module back to the manufacturing plant for repair. The relevant address is available from your Siemens contact person.

Always enclose the following information:

● Type and serial number

● Time and date of the failure

● Description of the fault profileSpecify what happened when the component failed.

● Operating point, currents and voltages

● Log file with fault messages

● Copy of the CompactFlash card

● If possible, hard copies from the plotter or screenshots

● Mounting locationSpecify the equipment identifier. You can find the item code on the component and close to the slot.

WARNING

Danger when components are incorrectly replaced

Incorrectly replacing components can result in death, serious injury, or material damage.● Only replace components that are described in the following sections. All other

components may only be replaced by Siemens service personnel. In this case, contact the Service Center.



9.7.1 Replacing the AVT combination module

WARNING

Danger caused by high voltages at the AVT combination module and the precision measuring resistors

The AVT combination modules and measuring resistors are at hazardous voltage levels. Touching these components can result in death, severe injury and significant material damage.● Never touch the AVT combination modules or measuring resistors under any

circumstances.

WARNING

Danger when making changes to the design of the voltage or ground fault detection

Changes to the voltage or ground fault detection, e.g. to the measuring resistors, are potentially lethal. This can result in substantial property damage, physical injuries and death.● Do not change the design of the voltage or the ground fault detection.

Removing the AVT combination module1. Follow "the five safety rules (Page 15)".

2. Release the control cables ①. Carefully ensure that you do not kink the fiber optic cables.

3. Remove the four fixing screws ② of the AVT combination module.

Figure 9-6 Example of an AVT combination module



Installing the AVT combination module1. Use the screws ② to secure the AVT combination module.

2. Reconnect the control lines ①. Do not bend the fiber-optic conductors.

9.7.2 Replacing the snubber circuit capacitor

WARNING


The snubber circuit capacitors are not equipped with discharge resistors. The energy stored in the capacitors is discharged via a circuit in the thyristor electronics. This circuit is interrupted when the thyristor electronics are withdrawn.

Voltages of up to several 1000 V can occur and cause an electric shock. This can result in death, severe injuries and significant material damage.● In this case you should always handle the capacitors as if they were charged.● Discharge the snubber circuit capacitors. Short-circuit the snubber circuit capacitors

before you withdraw the thyristor electronics.

Use the available threaded clamps for fixing the capacitors in place. Tighten the capacitor terminals with the following torques.

Table 9-2 Torques of the capacitor connections

Nuts Tightening torqueM10 7 NmM12 10 Nm

9.7.3 Replacing the CompactFlash cardTo replace the CompactFlash card, proceed as follows:

1. Ensure that the Control Unit is de-energized.

NOTICE

Destruction of the CompactFlash card

The CompactFlash card must only be inserted or removed when the power is off. Otherwise there is a risk of data loss or damage to the card, which would prevent commissioning of the drive.● Only remove or insert the CompactFlash card when the power is switched off.

2. Withdraw the CompactFlash card from the Control Unit. Back up the data saved on it.



3. Copy the stored data of the previous CompactFlash card to the new original Siemens card.

NoteInvalid software key

The software key is associated with the serial number of the CompactFlash card. If you overwrite the software key of the new CompactFlash card with the previous CompactFlash card, the new CompactFlash card is not operational.

Consequently, use the software key of the new CompactFlash card.

4. Insert the new Siemens CompactFlash card.

9.7.4 Replacing the differential pressure monitorProceed as follows to replace the differential pressure monitor:

1. The five safety rules must be observed.

2. Release the two connections of the differential pressure monitor.

3. Withdraw the air hose at the differential pressure monitor.

4. Release the two screws that are used to attach the differential pressure monitor.

5. Release the differential pressure monitor from the mounting plate.

6. Attach the new differential pressure monitor to the mounting plate.

7. Reinstall the new differential pressure monitor in the cabinet. Reconnect the cables and air hose.

8. After replacing the differential pressure monitor, adjust the switching point.

Setting the switching pointSet the switching point for the differential pressure during commissioning. Select the switching point so that when a fan is switched off, this will cause the differential pressure switch to trip after approximately 3 seconds. As a minimum, set differential pressure values of 500 Pa.

9.7.5 Replacing contactors

CAUTION

Injury when using incorrect contactors

Use of the wrong contactor can result in a malfunction and thus lead to physical injuries and material damage.● Always use contactors of the same type. Check the device numbers of the previous and

new contactors.



To replace the contactors, proceed as follows:

1. Loosen the cables. To do so, unscrew the screws.

2. Remove the contactor from the DIN rail.

3. Snap the new contactor onto the DIN rail.

4. Reattach the cables. Adhere to the markings. Do not interchange the cables.

5. Re-connect the protective circuit after replacing a contactor. Refer to the circuit diagrams to help you. You will find these in the section headed "Overview diagram, circuit diagram, terminal diagram" in the "Power Unit Circuit Manual".

9.7.6 Replacing the current transformer

Removing the current transformerTo remove the current transformer, proceed as follows:

1. Observe the five safety rules.

2. Switch off the power supply for the current transformer.

3. If the cores do not have core end markings, mark the connecting point.

4. Disconnect the 3-pole shielded cables for the measuring signal.

5. Remove the green/yellow ground wire connected to the insulated round rod.

6. Remove the fixing screws from the insulated round rod and the transformer.

7. Remove the current transformer from the cabinet.

See alsoThe 5 safety rules (Page 15)

Installing the current transformerTo install the current transformer, proceed as follows:

1. Carry out the removal steps in reverse order.

2. Screw the screws into the busbars with a tightening torque of 25 Nm.

3. After installing the current transformer, check that it works properly.



9.7.7 Replacing the thyristor electronics and thyristors

9.7.7.1 Check components of the thyristor assemblyIn the event of a thyristor assembly failing, establish which component has failed:

● Thyristor (by resistance measurement)When a thyristor fault message is output, the fault value indicates which thyristor is affected. Check the thyristor resistance while it is installed.

● Thyristor electronics (by replacement)Send the replaced thyristor electronic boards to the manufacturer for testing.

● Fiber-optic cablesReplace the fiber-optic cables according to the instructions for laying fiber-optic cables.

● Opto-transmitter / opto-receiver

● Suppressor capacitorsDefective snubber circuit capacitors may only be replaced on inserted thyristor electronics.

WARNING


The snubber circuit capacitors are not equipped with discharge resistors. The energy stored in the capacitors is discharged via a circuit in the thyristor electronics. This circuit is interrupted when the thyristor electronics are withdrawn.

Voltages of up to several 1000 V can occur and cause an electric shock. This can result in death, severe injuries and significant material damage.● In this case you should treat the capacitors as if they were charged.● Discharge the snubber circuit capacitors. Short-circuit the snubber circuit capacitors

before you withdraw the thyristor electronics.

Figure 9-7 Thyristor rack position



9.7.7.2 Replacing thyristor electronics

DANGER

Danger when not complying with the five safety rules

Non-observance of the five safety rules can cause death or serious injury. Serious material damage can also result.● Observe the five safety rules. ● Work must only be performed on adequately grounded power circuitry.

Two plug connectors are available on the thyristor electronics for connection to the thyristor and the external circuitry. The mating connector is integrated at the mounting position of the thyristor electronics.

If the thyristor electronics have to be replaced, proceed as follows:

Disconnecting the cablesTo disconnect the cables, proceed as follows:

1. If there are no core end markings, label the two fiber-optic cables and the connected cables.

2. Remove all connecting leads.

3. Detach the two fiber-optic cables from the opto-receiver and opto-transmitter modules.

4. Pull out the fiber-optic cables.

Changing the thyristor electronicsTo change the thyristor electronics, proceed as follows:

1. Take out the thyristor electronics. To do this, loosen the four screws with which the thyristor electronics are fixed to the carrier frame.

2. Send the defective thyristor electronics back. Refer to Notes on sending back (Page 133) to help you.

3. Install the new thyristor electronics. Tighten the screws with a tightening torque of 1.8 Nm.

Connecting cablesTo connect the cables, proceed as follows:

1. Reconnect the fiber-optic cables to the opto-transmitter and opto-receiver in accordance with the markings. Carefully hand-tighten the knurled nut.

2. Check the correct insertion depth of the fiber-optic cables with the aid of the marking rings.If the white colored ring on the fiber-optic cable is flush with the shaft end of the plug case, the fiber-optic cables are correctly inserted.

3. Reinsert the connecting leads into the thyristor electronics.

4. Check that everything is correctly connected and that the cables are correctly inserted.



Notes on sending backSend defective thyristor electronics to the manufacturer for repair. Please observe the following:

● Use suitable containers made of cardboard, wood or plastic for shipping.

● Use filler material to hold the thyristor electronics in place.

● Enclose dehumidification material if the packaging is air-tight.

● Note the ESD in the "Safety instructions" section.

NOTICE

Material damage due to inadequate packaging

Components can be bent by careless packing or insufficient packaging. This makes determining the exact cause of the error difficult.● When packing the thyristor electronics, take care not to bend protruding parts.

Note

Any information about the damage to the thyristor electronics will be helpful for determining the cause of the fault and for repair. Moreover, this data is evaluated for a reliability analysis.

Include information about the most recent operational performance and about any previous conspicuous behavior.

See alsoComponents that can be destroyed by electrostatic discharge (ESD) (Page 19)

9.7.7.3 Replacing a thyristor

The tool set provided contains the following parts:

● Open-ended wrench

● Socket wrench

● Contact oil "Cramolin Schutz" (international name "Cramolin Protection")

NoteSelecting replacement thyristors

Use only the approved thyristor types for the mounting location. Observe the equipment installation log when replacing the thyristor.



DANGER

Danger when not complying with the five safety rules

Work must only be performed on adequately grounded power unit. Non-observance of the five safety rules can cause death or serious injury. Serious material damage can also result.● Observe the five safety rules.

The thyristors are centered in the stack using their outer diameter and plastic bolts. The plastic bolts are attached to the heat sinks. A disk spring at the end of the stack provides the necessary pressure.



Removing a thyristor1. For thyristor stacks, detach the gate lead from the thyristor electronics.

① Guide bolt② Open-ended wrench

Figure 9-8 Open-ended wrench in the groove of the guide bolt

2. Insert the open-ended wrench ② into the groove of the guide bolt ①.

③ Socket wrench④ Clamping screw

Figure 9-9 Loosening the clamping screw with the socket wrench



3. Loosen the clamping screw ④ with the socket wrench ③.This releases the heat sink/thyristor assembly. As you do this, the heat sinks and thyristors move downwards until they are held in a defined position by holding bolts.

Note

The stack is fully released when the lowest heat sink is held by the holding bolt.

4. Remove the thyristor with the gate lead or the diode facing forwards.The holding bolts and the distances traveled are matched to each other so that you can easily remove the thyristor from the clamped assembly after releasing the clamping bolt.

Installing a thyristor1. Clean the surfaces of the thyristors and heat sinks with ethanol.

2. Apply a thin coat of the contact oil provided to the thyristor surfaces.

– To do this, spray the contact oil onto a lint-free cloth.

– Apply this to the contact surfaces of the thyristor.

3. Then immediately install the thyristor in the following sequence:

– Push the thyristor from the front against the plastic bolt on the heat sink.Make sure that the thyristor is correctly seated and centered. Pay attention to the mounting position, especially the polarity of the thyristor. The adhesive symbols on the clamping pressure plates show the appropriate information.

– Tighten the clamping screw ④ with the socket wrench ③ until the open-ended wrench ① can be easily removed.The clamping force has been correctly set when the groove of the steel bolt is flush with the surface of the upper plate.

– Enter the thyristor numbers and the replacement data in the equipment installation log.The first number on the thyristor label is the thyristor number.

– Reconnect the gate lead. Ensure that the lead is correctly twisted.

9.7.7.4 Disconnecting the fiber-optic cables

Tools requiredYou require a fiber-optic cable cutter (Order No. A5E02615209) to cut the fiber-optic cables to length.



Procedure

NOTICE

Destruction of the fiber-optic cables

Fiber-optic cables can be destroyed under the following conditions: ● The bending radius is less than 20 mm.● The fiber-optic cables are subject to strong light.● The fiber-optic cables are exposed to temperatures of over 80° C.

Handle the fiber-optic cables carefully. Do not bend them with a bending radius of less than 20 mm. Protect the fiber-optic cables from heat and strong light.

① Knurled nut② Fiber-optic cable

Figure 9-10 Releasing a fiber-optic cable

To disconnect the fiber-optic cables, proceed as follows:

1. Carefully unscrew the knurled nut ①.

2. Pull the fiber-optic cable ② out.

3. Insert the new fiber-optic cable as far as it will go. If correctly fitted, the white ID ring must be flash with the opto-transmitter or opto-receiver.

4. Tighten the knurled nut ① again by hand.

9.7.8 Replacing surge arrestersTo replace the surge arrester, proceed as follows:

1. Release the screws.

2. Remove the defective surge arrester.

3. Insert the new surge arrester.

4. Screw the surge arrester in place with the following torque:3EK7 = 40 Nm3EJ2 = 70 NmThe surge arrester must not be subject to a transverse force greater than 370 N.



9.7.9 Replacing the DC-link reactor

Establishing and grounding the power connectionsThe power connections are made by the expansion straps. To establish and ground the power connections, proceed as follows:

1. Clean and grease the contact surfaces immediately before screwing in the connections.For this purpose, use the cleansing agents and greases listed in the table below.

Medium DescriptionCleaning agent Ethyl alcohol and lint-free clothGrease Electrolube 2G or equivalent contact lubricant

2. Screw in the connections. The tightening torque of the M12 screw connections supplied is 50 Nm.

3. Ground the DC link reactor by the cabinet grounding cable.



Spare parts 10NOTICE

Damage due to non-authorized spare parts

Using non-approved spare parts can affect the function of the equipment and damage it. Third-party spare parts and unapproved spare parts may not meet the requirements.● Therefore, only use spare parts that have been approved by the manufacturer.

To request spare parts, please contact the Siemens sales office responsible for your region.You can find an overview of the Siemens contact partners in your region here (www.siemens.com/services/partner).

Note

Always indicate the part number and - if known - the order number of the spare part required. You can find the order number as follows:

The device label is attached to or next to each component. Find out which item code the required spare part has. The parts list provided specify the part number and, where appropriate, the article number corresponding to the equipment identifier. For inquiries by e-mail, if possible send a photograph of the product, spare part, rating plate.

Use Spares on Web (https://b2b-extern.automation.siemens.com/spares_on_web(bD1kZSZjPTA4MCZkPW1pbg==)/default.htm) to obtain information about spare parts.

The following parts list contains information about the components installed. The data in this list can be used for ordering spare parts.


http://www.siemens.com/services/partner

https://b2b-extern.automation.siemens.com/spares_on_web(bD1kZSZjPTA4MCZkPW1pbg==)/default.htm

https://b2b-extern.automation.siemens.com/spares_on_web(bD1kZSZjPTA4MCZkPW1pbg==)/default.htm

Spare parts


Disposal 11When carrying out any work, carefully observe the information provided in Chapter "Safety instructions (Page 15)".

11.1 Disposing of packaging materialThe packing is designed in such a way as to pose the minimum risk to the environment. Some of the packaging can be recycled.

The disposal of packaging is controlled by country-specific laws. If in doubt, ask your local disposal specialists or contact the local authorities.

The packing material consists of the following components:

● Wooden frames

● Wooden pallets

● Polyethylene foil

● Plywood

● Plastic

● Silica gel

11.2 Removing device components and old devicesIf you correctly dispose of the materials, none of the materials pollutes the environment. When disposing or reusing, comply with the local laws and regulations.

WARNING

Improper disassembly

In the event of an improper procedure during disassembly, material can slip, tilt, and fall down. This can result in death, serious injury or material damage.● Only specialist personnel may disassemble and dispose of device components and old

devices using appropriate protective clothing.● Shut down the device before disassembling. Ground the device● With old devices, also follow the instructions in the section "Transport."

For the following components, pay special attention when disposing or reusing:

● Batteries

● Capacitors


● PCBs

● Electronic components

Disposal11.2 Removing device components and old devices


Service & Support AA.1 Siemens Industry Online Support

Technical questions or additional information

If you have any technical questions or require additional information, please contact Technical Support (https://support.industry.siemens.com/cs/ww/en/sc/2090).Please have the following data ready:● Type● Serial numberYou can find this data on the rating plate.

Contact person

If you wish to request on-site service or order spare parts, please contact your local office. This office will contact the responsible service center on your behalf. You can find your contact person in the relevant contact data‐base:www.siemens.com/yourcontact (www.siemens.com/yourcontact)


https://support.industry.siemens.com/cs/ww/en/sc/2090

https://support.industry.siemens.com/cs/ww/en/sc/2090

http://www.siemens.com/yourcontact

A.2 SIOS App

Siemens Support for on the move

With the "Siemens Industry Online Support" App, you can access more than 300,000 documents for Siemens Industry products – any time and anywhere. The App supports you in the following areas:● Resolving problems when executing a project● Troubleshooting when faults develop● Expanding a system or planning a new systemFurther, you have access to the Technical Forum and other articles that our experts have drawn-up: ● FAQs● Application examples● Manuals● Certificates● Product announcements and many moreThe app is available for Apple iOS, Android and Windows Phone.

Service & SupportA.2 SIOS App


Technical specifications and drawings B

NoteFinding technical data and drawings

The technical data and the necessary drawings can be found in "Technical data and drawings" manual.

B.1 Standards and regulations

Table B-1 Standards and regulations

DirectivesStandards DIN EN 61800‑3/VDE 0160 Part 103 (IEC 61800-3)

DIN EN 61800‑4 / VDE 0160 T104 (IEC 61800-4); only to the extent that it can be appliedDIN EN 61800‑5‑1/VDE 0160 Part 105 (IEC 61800-5-1)DIN EN 60146‑1‑1 / VDE 0558 T11 (IEC 60146-1-1); only to the extent that it can be appliedDIN EN 60204‑11 / VDE 0113 T11 (IEC 60204-11); only to the extent that it can be applied

EU directives Machinery Directive: 2006/42/EC + amendmentsElectromagnetic compatibility:2014/30/EU + amendments

CE marking According to Low Voltage Direction (only applies to the low-voltage parts, e.g. the control cabinet2014/35/EU + amendments

Protection class Class 1 in accordance with DIN EN 61140/VDE 0140 Part 1 (IEC 61140)Touch protection BGV A3Insulation According to DIN EN 61800‑5‑1 / VDE 0160 T105 (IEC 61800-5-1): Pollution

degree 2 (without conductive pollution), non-condensingRadio interference level

According to DIN EN 61800-3/VDE 0160 Part 100 (IEC 61800-3): no RI sup‐pression

Environmental condi‐tions

DIN EN 60721-3-1/2/3 (IEC 60721-3-1/2/3)


The EC declaration of conformity for the product described here, which complies with the European Directive 2006/95/EC and corresponding standards EN 61800-5-1 and EN 60204-1, refers only to the low-voltage section in the power unit and the control cabinet.

B.2 Environmental conditions

Climatic environmental conditions

Table B-2 Climatic environmental conditions

Storage with suitable packag‐ing

Transport with suitable pack‐aging

Operation (industrial)

Ambient temperature -25° C to +70° C -25° C to +70° C 5° C to +40° CRelative humidity 5% to 95%

(Only low condensation is permitted. The device must be completely dry before commissioning.)

5% to 75% 5% to 85%(Condensation is not permit‐ted)

Other climatic conditions ac‐cording to class

1K3 according to DIN EN 60721‑3‑1 (IEC 60721‑3‑1)



Pollution degree 2 without conducting contam‐ination according to DIN EN 61800-5-1 / VDE 0160 T105 (IEC 61800-5-1)

2 without conducting contam‐ination according to DIN EN 61800-5-1 / VDE 0160 T105 (IEC 61800-5-1)

2 without conducting contam‐ination according to DIN EN 61800-5-1 / VDE 0160 T105 (IEC 61800-5-1)

Mechanical ambient conditions

Table B-3 Mechanical ambient conditions



Operation

Class 1M2 according to DIN EN 60721‑3‑1 (IEC 60721‑3‑1)

2M2 according to DIN EN 60721‑3‑2 (IEC 60721‑3‑2)

3M1 according to DIN EN 60721‑3‑3 (IEC 60721‑3‑3)

Technical specifications and drawingsB.2 Environmental conditions


Other ambient conditions

Table B-4 Other ambient conditions



Operation

Biological ambient conditions according to class

1B1 according to DIN EN 60721‑3‑1 (IEC 60721‑3‑1)

2B1 according to DIN EN 60721‑3‑2 (IEC 60721‑3‑2)

3B1 according to DIN EN 60721‑3‑3 (IEC 60721‑3‑3)(without harmful flora)

Chemically active substan‐ces according to class

1C1 according to DIN EN 60721‑3‑1 (IEC 60721‑3‑1)



Mechanically active substan‐ces according to class

1S1 according to DIN EN 60721‑3‑1 (IEC 60721‑3‑1)





Index

""Siemens Industry Online Support" App, 144

55 safety rules, 15

AActual value sensing

Current actual value sensing, 33Voltage actual value sensing, 33

Anti-condensation heating, 47, 52AOP30 operator panel

Function, 42Replacing the backup battery, 123

Auxiliary voltageFailure of the auxiliary voltage, 116Interference suppression, 84

AVT combination module, 33

BBridge short-circuit, 37

CCable cross section

Ground connection to the peripherals, 84Protective ground conductor, 22

Cable lengthDRIVE-CLiQ interface, 44

Circuit breaker, 35Clamped thyristor assembly, 32Cleaning aluminum parts, 125Commutation errors, 37CompactFlash card

Replacing, 128Components that can be destroyed by electrostatic discharge (ESD)

Guidelines, 19Connecting the signal lines, 89Converter bridge, 37Current conduction permanent signals, 37

Current transformer, 34, 36Torque, 130

DDC link reactor, 33dI/dt reactor, 49Differential-pressure switch, 35Direction of rotation changeover, 100Door interlock

Cover screw, 69Electromechanical, 28, 35, 115Manual, 69Safety locking system, 115

DRIVE-CLiQ, 34

EElectromagnetic fields, 18Elements in the door

Indicator lights, 41Environmental conditions, 146

FFan, 35

Replacing, 119Fiber-optic cables, 37, 137Filter mats, 119, 122Fuse

Power Stack Adapter, 106

GGate pulses, 37Ground fault, 104Grounding

ESD shoe grounding strips, 19Grounding concept, 22Grounding device, 114Grounding harness, 113Grounding point, 82Grounding points, 114High voltage after shutdown, 113Insufficient grounding, 90Protective ground conductor, 22


Shield busbar, 22Shield connection, 82

IInsulation monitoring, 104Insulation resistance, 104Inverter shoot-through, 37

LLeakage reactance, 36LEDs

Power Stack Adapter, 106Sirius safety relay, 105

Line-side converter, 33, 36Load current zero signal, 37

MMinimum speed, 100Monitoring

Communication between the closed-loop control and power unit, 29Failure of the control components, 29Internal protection functions for the control hardware, 29Monitoring functions and protective devices, 22Semiconductor failure, 29Shock and tilt indicators, 60

More information, 143Motor-side converter, 33, 36

OOn-site service, 143

PParameter categorization, 99Parameter types, 98Power Stack Adapter, 34, 37Protection and monitoring functions

External components, 29Internal components, 29

PSA, 34, 37

RRamp-function generator, 101RC circuit, 31, 37Rounding times, 101

SSafety concept, 29Safety information

Failure of a thyristor assembly, 131Fiber-optic cables, 137

Setpoint addition, 100Shock and tilt indicators

Location, 61Purpose, 60

Short-circuiting, 36Siemens Industry Online Support

App, 144Snubber circuit capacitor, 128Spare parts, 143

Contact person, 139Spares On Web, 139

Speed limitation, 100Storage

Drive unit, 70Fan, 71, 119General specifications, 70Preconditions, 70Storage duration, 71, 119

Suppression bandwidths, 100Surge arresters, 35Surge suppressor, 137

TTAS CPLD, 33, 37Technical Support, 143Thyristor, 37Thyristor assembly, 131Thyristor electronics, 37, 132Thyristor electronics power supply, 37Thyristor stack, 31Thyristor state, 37Thyristors, 134Time-coded feedback signals, 37Transformer, 53, 54

Step-down, 47, 50Step-up, 47, 50, 54

Index


UUM sensing, 38

VVector control, 102Voltage Sensing Module

VSM, 45

Index


Index


0009938503 000030 01 EN 01

*000993850300003001EN01* 000993850300003001EN01

Further Informationwww.siemens.com/LDASiemens AGLarge Drives ApplicationsVogelweiherstr. 1-1590441 NÜRNBERGGERMANY

Large Drives Applications

Siemens AG, DI MC CBMF MF-NMA LDA EN, Postfach 47 43, 90025 Nürnberg

PD LD AP BA OMYasmin MarxGugelstr. 65

D-90459 Nürnberg

Department DI MC CBMF MF-NMA LDA ENTel. +49 (911) 433-6422Fax +49 (911) 433-6921Email [email protected]

mOur ref. 0009938503000030Date 28.10.2019

Documentation for 6SL38503UN116AA0ZYour order no. 4500342954 - 000030

AL: N ECCN: N UL: DEStWanr (CD): 85234045, StWanr (Print): 49011000

Dear Sir / Madam,

Many thanks for your order, the documentation for which is enclosed.

Yours very truly,

*000993850300003001EN01*

Spine label for binder 50 mm (120 g/m2)

SINAMICS GL1506SL38503UN116AA0Z

EXAMPLE

Operating Instructions

Spine label for binder 145 mm (120 g/m2)

SINAMICS GL150 6SL38503UN116AA0ZEXAMPLE

Operating Instructions / Installation Instructions

Medium-Voltage Drive - Siemens

Documents

Transcript of Medium-Voltage Drive - Siemens