Siemens Drives & PLCs Answers for industry.

Transcription

1 SINAMICS S120 Applications for Cabinet Modules, liquid-cooled Operating instructions Edition 04/2015 Siemens Drives & PLCs Answers for industry.

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3 Introduction Safety notes 1 SINAMICS S120 Applications for Cabinet Modules, liquid cooled Operating Instructions Description 2 Preparations for use 3 Installation 4 Electrical connection 5 Commissioning 6 Operation 7 Servicing 8 Spare parts 9 Disposal 10 Service & Support Technical data Checklists and forms A B C Siemens Drives & PLCs 04/2015 A5E A

4 Legal information Warning notice system This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are graded according to the degree of danger. DANGER indicates that death or severe personal injury will result if proper precautions are not taken. WARNING indicates that death or severe personal injury may result if proper precautions are not taken. CAUTION indicates that minor personal injury can result if proper precautions are not taken. NOTICE indicates that property damage can result if proper precautions are not taken. If more than one degree of danger is present, the warning notice representing the highest degree of danger will be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property damage. Qualified Personnel The product/system described in this documentation may be operated only by personnel qualified for the specific task in accordance with the relevant documentation, in particular its warning notices and safety instructions. Qualified personnel are those who, based on their training and experience, are capable of identifying risks and avoiding potential hazards when working with these products/systems. Proper use of Siemens products the following: Trademarks WARNING Siemens products may only be used for the applications described in the catalog and in the relevant technical documentation. If products and components from other manufacturers are used, these must be recommended or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and maintenance are required to ensure that the products operate safely and without any problems. The permissible ambient conditions must be complied with. The information in the relevant documentation must be observed. All names identified by are registered trademarks of Siemens AG. The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner. Disclaimer of Liability We have reviewed the contents of this publication to ensure consistency with the hardware and software described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in this publication is reviewed regularly and any necessary corrections are included in subsequent editions. Siemens AG Division Process Industries and Drives Postfach NÜRNBERG GERMANY Order number: Review_A5E A P 04/2015 Subject to change Copyright Siemens AG All rights reserved

5 Introduction About these instructions These instructions describe the drive and explain how to handle it, from initial delivery to final disposal of the equipment. Keep these instructions for later use. Read these instructions before you handle the drive and follow the instructions. The instructions contain information about the safe handling of the drive as well as its components and modules. They provide information on assembling, installing, and maintaining the equipment properly. If you have suggestions for improving the document, please contact our Service Center (Page 139). Text format features The warning notice system is explained on the rear of the inside front. Always follow the safety instructions and notices in these instructions. In addition to the safety-related warning notices which you must read, you will find the text in these instructions is formatted in the following way: 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. A is an important item of information about the product, handling of the product or the relevant section of the document. s provide you with help or further suggestions/ideas. Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 5

6 Introduction 6 Operating Instructions, 04/2015, A5E A

7 Table of contents Introduction Safety notes Qualified personnel The five safety rules Safe handling Electromagnetic fields in electrical power engineering installations Components that can be destroyed by electrostatic discharge (ESD) Information for persons responsible for plants and systems Proper usage Grounding concept Installation site safety Instructions for inverters with no grounding switch Measures for operator protection in electromagnetic fields Residual risks Description Overview Field of application Benefits System structure Description of the components Line Connection Module Basic Line Module Active Line Module Motor Modules Central Braking Module Auxiliary Power Supply Modules Re-cooling unit Description of the optional components AOP30 Advanced Operator Panel Output-side circuit-breaker Operation in an IT supply system CBC10 Communication Board CBE20 Communication Board Control Unit CU320-2 DP; Control Unit PN dv/dt filter compact plus Voltage Peak Limiter du/dt filter plus Voltage Peak Limiter EMC shield bus Grounding switch downstream of main breaker Grounding switch upstream of main breaker...32 Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 7

8 Table of contents Holder for ARC detector Main contactor for Line Connection Modules < 800 A Auxiliary power generation in the Line Connection Module Insulation monitoring Cable-marshaling compartment 200 mm high Circuit breaker in withdrawable unit design Fan power supply Measuring device for line supply variables Measuring device for line supply variables with PROFIBUS connection Motor reactor Line connection from above TM150 Temperature Sensor Module Terminal Module TM54F Safe Brake Adapter SBA 230 V AC Closed cabinet door (air inlet from below through floor opening) IP21 degree of protection Degree of protection IP IP43 degree of protection IP54 degree of protection Contactor monitoring SMC10 Sensor Module SMC20 Sensor Module SMC30 Sensor Module SMC30 Sensor Module, additional Base 100 mm high Anti-condensation heating Current transformer upstream of the main switch Voltage Sensing Module VSM Preparations for use Requirements regarding the installation site Inspections when the equipment is received Checking the delivery Checking shock and tilt indicators Checking the load handling attachments Transport Transport markings Transport requirements Take the center of gravity into account Transport with a fork-lift truck Transporting using a crane Transporting transportation units packed in boxes Disassembling the crane transport assembly Unpacking the cabinets Removing the packaging Removing load securing devices Lifting the cabinet units off the transport pallet and installing them Checking the shock and tilt indicators inside the cabinet Storage Emptying the drive Operating Instructions, 04/2015, A5E A

9 Table of contents Storing a device Forming DC link capacitors Storing re-cooling units Draining the cooling circuit Installation Safety instructions for assembly Tools required Torques Connecting to the foundation Connections of transport units Connecting the collecting pipes of the cooling circuit Connecting the converter system with the cooling unit Connecting cabinets Connecting the DC and PE busbars Connecting the DC busbar Connecting the PE busbar Connecting-up according to the plant-side grounding concept Connecting cables brought out to the PE busbar Electrical connection Safety instructions for electrical connections Electromagnetic compatibility Connection Preparations for connecting the power cables Connecting the motor cable Line/power connections Connecting the ground Connection according to the system-side grounding concept Connecting external cables to the PE busbar Operation on an isolated line supply (IT supply system) Signal connections Other connections Fastening the cable ducts with cable ties Cable routing Basic rules for cable routing Safety and EMC Cable routing for Basic Line Modules Cable routing for PROFIBUS or PROFINET connections to the Control Unit Cable routing for DRIVE-CLiQ connections and signal cables Cable routing to the customer terminal block -X Cable routing for Motor Modules Cable routing for PROFIBUS or PROFINET connections to the Control Unit Cable routing for DRIVE-CLiQ connections and signal cables Cable routing to the customer terminal block -X Cable routing for the Terminal Module TM54F Cable routing for signal cables to SMC10/20/30 Sensor Module Cable routing to connect the motor Cable routing for Active Line Modules...91 Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 9

10 Table of contents Checklist Cable routing for PROFIBUS or PROFINET connections to the Control Unit Cable routing for DRIVE-CLiQ connections and signal cables Commissioning Commissioning the drive Commissioning the cooling unit Anti-condensation measures Filling the cooling circuit Venting the cooling circuit Commissioning Control of the cooling unit Programming the interface Operation Safety instructions for operation Fault and system messages Diagnostics Fault messages from the cooling unit Servicing Safety instructions for maintenance Preventive maintenance Inspection Maintenance intervals Visual inspections Tools required Torques Servicing the cabinet Checking the isolating clearances Checking the plug connections Checking the cable and screw terminals Checking the filter mats Waiting Replacing filter mats Replacing the back-up battery of the AOP30 operator panel Loading operator panel firmware, parameter and signal descriptions Maintaining the cooling circuit Servicing the filter for a cooling unit supplied from Siemens Maintaining and replacing coolant hoses Maintaining the pumps Maintaining the fans of the additional cooler Cleaning Removing dust deposits Cleaning frame components Cleaning aluminum parts Repairs Replacing power components Installation device for chassis units Operating Instructions, 04/2015, A5E A

11 Table of contents Removing Basic Line Modules Removing Active Line Modules Removing Motor Modules Installing power unit components Replacing the fan of the Active Interface Module Replacing the fan of the additional cooler (degree of protection IP54) Removing the fan of the 3 kw additional cooler Removing the fan of the 0.8 kw additional cooler Installing the fan of the additional cooler Replacing the fuses Replacing DC fuses Replacing AC fuses Spare parts Disposal A B C 10.1 Disposing of packaging material Removing device components and old devices Service & Support A.1 Siemens Industry Online Support Technical data B.1 General technical system data B.2 Specification of the untreated water Checklists and forms C.1 Mechanical installation: Checklist C.2 Electrical installation: Checklist Index Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 11

12 Table of contents 12 Operating Instructions, 04/2015, A5E A

13 Safety notes 1 In the individual chapters of this document, you will find safety instructions that must be obeyed absolutely, for your own safety, to protect other people and to avoid damage to property. Pay attention to the following safety instructions for all activities on the inverter. 1.1 Qualified personnel The product/system described in this documentation may only be operated by personnel qualified for the specific task in accordance with the relevant documentation for the specific task, in particular its warning notices and safety instructions. Because of their training and experience, qualified personnel can recognize any risks involved with handling these products/ systems and avoid any possible dangers. 1.2 The five safety rules For your personal safety and to prevent material damage when carrying out any work, always observe the safety instructions and the following five safety rules, according to EN "Dead working". Apply the five safety rules in the sequence stated before starting work. Five safety rules 1. Disconnect completely. Disconnect the auxiliary circuits, for example anti-condensation heating. 2. Secure against reconnection. 3. Verify absence of operating voltage. 4. Carry out earthing and short-short-circuiting. 5. Provide protection against adjacent live parts. To energize the system, apply the measures in reverse order. Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 13

14 Safety notes 1.3 Safe handling 1.3 Safe handling WARNING High voltages during operation When operating this equipment very high voltages develop. Even after switching off the mains voltage, or while the connected machine is still turning, high voltages can remain for a prolonged length of time. High voltages can cause death or serious injury if the safety rules are not observed or if the equipment is handled incorrectly. Operate the drive properly. Always follow the "The five safety rules (Page 13)" when performing any work. Only remove the covers using the methods described by these operating instructions. Maintain the drive regularly and correctly. WARNING High voltages from machines still turning and connected A rotating machine represents a risk as it can induce dangerous high voltages that are not immediately de-excited. If the connection to the motor is not isolated or grounded, these voltages can also remain. If live parts are touched, this can result in death and serious physical injuries. Before opening the doors, wait until the connected machine has come to a standstill. WARNING High voltages from DC link capacitors After the mains voltage has been switched off with the "EMERGENCY STOP" pushbutton, high voltages are still present at the DC link capacitors. In the event of improper handling or non-observance of the safety instructions, death or serious injury could result. Wait for the DC link capacitor's discharge time specified on the label on the device. Do not touch the device during this time. Observe the five safety rules when performing any work. WARNING High auxiliary voltages High auxiliary voltages are still present even after shutdown. If live parts are touched, this can result in death or serious physical injury. Observe the five safety rules when performing any work. 14 Operating Instructions, 04/2015, A5E A

15 Safety notes 1.3 Safe handling WARNING Hazardous arcing Hazards caused by arcing can occur as result of the following factors, for example: The input currents are exceeded Incorrectly dimensioned circuit breaker or transformers Incorrectly connected cables or cables that have not been connected Excessive pollution 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 any excessive pollution. WARNING Live, 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 necessary covers. WARNING Hot component surfaces Certain components (e.g. heat sinks and reactors) can become very hot during operation. These components can remain hot for a long time after operation. Contact can result in serious injury, such as skin burns. Do not touch hot components even after you have switched off the drive. WARNING Hot anti-condensation heating surface When the temperature control limit value is reached the anti-condensation heating is switched on. Once activated, the anti-condensation heating can generate a great deal of heat. Contact can result in serious injury, such as skin burns. Do not touch the anti-condensation heating. Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 15

16 Safety notes 1.4 Electromagnetic fields in electrical power engineering installations CAUTION Places that are difficult to access If you do not use appropriate protective equipment when working in places that are difficult to access you are at risk of injury. For example, sharp edges and splinters can cause injuries to the head and skin. If you use unsuitable steps when working on the upper areas of the drive, you can fall and injure yourself. Use appropriate protective equipment, especially a hard hat and gloves. In the upper areas of the drive, use suitable steps. Coolant CAUTION The coolant is harmful to eyes and skin and can damage surfaces. Therefore, wear appropriate protective clothing for all work on the inverter. However, if your eyes or skin do come into contact with coolant, rinse the affected area thoroughly with tap water as soon as possible. If coolant leaks, eliminate the source of the problem and remove the liquid from the surfaces affected. 1.4 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. People with pacemakers are therefore not allowed to stay close to the drive. 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. For nominated persons in control of an electrical installation, you can find further information on electromagnetic fields under "Information for nominated persons in control of an electrical installation." 16 Operating Instructions, 04/2015, A5E A

17 Safety notes 1.5 Components that can be destroyed by electrostatic discharge (ESD) See also Information for persons responsible for plants and systems (Page 18) 1.5 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, transporting, 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, then 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 Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 17

18 Safety notes 1.6 Information for persons responsible for plants and systems a b c d e f Sitting Standing Standing/sitting Conductive floor surface, is only effective in conjunction with ESD shoes or ESD shoe grounding strips ESD furniture ESD shoes or ESD shoe grounding strips are only effective in conjunction with conductive flooring ESD clothing ESD wrist strap Cabinet ground connection Figure 1-1 ESD protective measures 1.6 Information for persons responsible for plants and systems Proper usage The drives are intended to be used as a stationary installation in closed and dry rooms with a clean atmosphere. You can find the environmental and operating temperatures that are to be adhered to in the technical specifications. If the described environmental conditions are not complied with, then warranty claims and other claims may be rejected. WARNING Explosions If you operate the drive in areas with a risk of explosion, explosions can occur which can cause death, serious injuries or material damage. Only operate the converter in a non-explosive environment (no hazardous zones). 18 Operating Instructions, 04/2015, A5E A

19 Safety notes 1.6 Information for persons responsible for plants and systems WARNING Non-observance of proper usage Improper use of the devices described can result in death, severe injury or material damage. Therefore, please adhere to all instructions for proper usage. 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 listed in the directives, specified in the "Technical specifications" in Section "Standards and regulations". Ensure that the specific safety and construction regulations and regulations for using personal protective equipment are adhered to during all work. The operating instructions and the complete product documentation are always available when carrying out any work. The technical specifications 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 drive. 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. Further system components such as the circuit-breaker, transformer, cables, and motor are adjusted for drive operation. The drive 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 139)". Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 19

20 Safety notes 1.6 Information for persons responsible for plants and systems Grounding concept Create a grounding concept and integrate the drive within it. The grounding concept must take into consideration national provisions and system specifics. Ensure that the following criteria are fulfilled: The drive sub-units must be screwed together with good conductivity on the construction site. If grounding bars are provided, these must be connected together. When the drive is supplied with power, the protective earth conductor must be connected to the system's grounding point. Select the cross-section of the protective ground conductor from one of the following variants: According to local wiring regulations Calculated according to IEC , Half a phase conductor cross-section Installation site safety WARNING Unsafe installation sites This drive is used in industrial high-voltage 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 drive 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. Put up notices which indicate that only trained personnel are allowed to operate the drive and carry out maintenance and repair work. Installations that include drive drives need to be equipped with additional monitoring and protection equipment to fulfill the safety requirements, e.g. technical equipment regulations, accident prevention regulations, etc. 20 Operating Instructions, 04/2015, A5E A

21 Safety notes 1.7 Residual risks Instructions for inverters with no grounding switch The drive does not have a grounding breaker at the input/output. The system operator must, therefore, ensure that there is sufficient grounding Measures for operator protection in electromagnetic fields The plant operator is responsible for taking the following appropriate measures (labels and hazard warnings) to adequately protect operating personnel against any possible risk. Observe the relevant nationally applicable health and safety regulations or the applicable national regulations in the country of installation. In Germany, "electromagnetic fields" are subject to regulations BGV B11 and BGR B11 stipulated by the German statutory industrial accident insurance institution. Display adequate hazard warning notices on the installation. Place barriers around hazardous areas. Take measures, e.g. using shields, to reduce electromagnetic fields at their source. Make sure that personnel are wearing the appropriate protective gear. 1.7 Residual risks According to the EU machinery directive, machine manufacturers / plant operators must conduct a risk assessment of their machine. Plant operators must conduct a risk assessment of their plant. In particular, pay attention to Annex 1 "General Principles" of the EU machinery directive. Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 21

22 Safety notes 1.7 Residual risks Pay attention to the following residual risks: 1. Unintentional movements of driven machine parts Unintentional movements of driven machine parts can occur during commissioning, operation, maintenance, and repair, e.g. from the following causes: Hardware defects and/or software errors in the sensors, controllers, actuators, and connection technology Response times of the controller and drive Operating and/or environmental conditions outside of the specification Condensation/conductive contamination Parameterization, programming, cabling, and installation errors Use of radio devices/cellular phones in the immediate vicinity of the controller External influences/damage 2. High temperatures and emissions A fault can occur as a result of the following, for example: Component malfunctions Software errors Operating and/or environmental conditions outside of the specification External influences/damage A fault can, for example, have the following consequences both inside and outside the drive: Extraordinarily high temperatures, including open fires as a result of the fault Emissions of light, noise, particles or gases Drives with open type / IP20 degree of protection must be installed in an electrical room or a comparable environment. 3. Hazardous shock voltages Hazardous shock voltages can result from the following causes, for example: Component malfunctions Induction of voltages in moving motors Operating and/or environmental conditions outside of the specification Condensation/conductive contamination External influences/damage 4. The release of substances and emissions that are harmful to the environment Improper operation or the improper disposal of components can harm the environment. 22 Operating Instructions, 04/2015, A5E A

23 Safety notes 1.7 Residual risks 5. Damage from pressure build-up during electric arcs in the event of a fault If the building has not been designed correctly for the drive in terms of how it has been dimensioned, damage can result from the pressure that can possibly build up inside. 6. Dangerous electric arcs during internal faults The drives are designed according to the relevant IEC standards and have been 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 work on the drive. Observe the safety and operating instructions in this documentation and on labels at the drive for all work on the drive. Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 23

24 Safety notes 1.7 Residual risks 24 Operating Instructions, 04/2015, A5E A

25 Description Overview Cabinet Applications are components of a modular cabinet unit system. The system is typically for multi-axis drives with central supply infeed and a common DC link busbar. Typical applications include, for example, paper machines, rolling mills, test stands, cranes. All drive components, from the supply infeed to the motor-side inverters, are configured in a clear, compact layout in the individual Cabinet Applications. Cabinet Applications can be combined with great flexibility and can be optimally adapted to customer-specific requirements thanks to a comprehensive array of options. The main components of the system are as follows: Line Connection Modules with line-side components such as contactors, fuses and circuit breakers, as well as line reactors for Basic Line Modules. Line Modules for the infeed using Basic Line Modules for 2-quadrant operation and Active Line Modules for 4-quadrant operation with line harmonics that can be neglected Motor Modules Control Units Standardized interfaces for both the power and the control connections facilitate configuration and installation. Communication between the power modules and the central Control Unit is established via DRIVE-CLiQ, the drive-internal serial interface. = ~ = ~ = ~ = ~ = ~ = ~ = ~ = ~ = ~ = ~ = ~ M 3~ M 3~ M 3~ M 3~ M 3~ M 3~ M 3~ M 3~ M 3~ M 3~ M 3~ M 3~ Figure 2-1 Example of a drive line-up for a multi-motor drive 2.2 Field of application The modular drive system is used where several motors have to be coordinated in a drive lineup to realize a multi-axis drive application. Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 25

26 Description 2.3 Benefits Typical examples include: Paper machines Roller mills Hoisting gear Test stands Further, single-motor drives with high power ratings can be implemented (parallel connection). 2.3 Benefits The outstanding system properties offer companies operating plants and systems the following advantages: Process optimization with minimal effort: A standard PROFIBUS or PROFINET interface and various analog and digital interfaces allow them to be easily integrated into automation solutions. Vector control ensures that they fulfill the most exacting requirements regarding the accuracy and dynamic response of drives. High level of reliability and availability: Individual modules and power components can be replaced quickly and easily, which ensures a higher level of plant availability. Energy savings during operation: The motor-side inverters are coupled via the common DC link and allow energy to be exchanged between motors that are motoring and generating. This means that energy is saved, there is less load on the supply infeed and line harmonics are reduced. The supply infeed is generally only dimensioned for the maximum motor power required / maximum motor current and not the sum of the energy requirements of the Motor Modules connected to the DC link. For example, for conveyor systems or engine test stands with Motor Modules that are simultaneously in the motoring and regenerative mode, this frequently results in smaller line supplies. Cost minimization during operation, maintenance, and service: Simple commissioning thanks to the menu-driven "STARTER" commissioning tool. Optional, menu-assisted AOP30 Advanced Operator Panel with plain text display and bar-type display. All the unit modules are easily accessible, offering a maximum degree of service friendliness. Space-saving design Environmentally-friendly operation: The converters are exceptionally quiet and compact thanks to state-of-the-art IGBT power semiconductors and an innovative cooling concept. 26 Operating Instructions, 04/2015, A5E A

27 Description 2.5 Description of the components 2.4 System structure Line Modules are coupled with the various Motor Modules using prefabricated DC busbar sets with different current ratings. Control Units, Line Modules and Motor Modules, and other active SINAMICS components communicate via DRIVE-CLiQ connections. DRIVE-CLiQ is an internal serial interface of the drive that enables fast and easy configuration of the complete drive configuration with prefabricated cables in varying lengths. The Cabinet Applications are delivered in preconfigured transport units with a total length of up to 2400 mm each. 2.5 Description of the components Refer to the layout diagrams and circuit diagrams provided on the customer DVD supplied with the unit for the arrangement of components and interfaces and for wiring Line Connection Module The Line Connection Modules contain the line-side infeed via main switch with fuse switch disconnector or circuit breaker. The Line Connection Module connects the plant-side supply with the Line Modules. You can find a description of the Line Connection Modules in the "SINAMICS S120 Cabinet Modules" Manual, Chapter, "Cabinet Modules / Line Connection Modules" Basic Line Module The Basic Line Modules are used to feed the DC link. The Basic Blank Modules are suitable for applications where no regenerative energy is produced, or where energy is exchanged between the motoring and generating axes in the DC link. You can find a description of the Basic Line Modules in the "SINAMICS S120 Power Units Chassis Liquid Cooled" Manual, Chapter "Line Modules / Basic Line Modules". Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 27

28 Description 2.5 Description of the components Active Line Module Active Line Modules can supply motoring energy and feed back regenerative energy into the line supply. If required, Active Line Modules can provide reactive power compensation. You can find a description of the Active Line Modules in the "SINAMICS S120 Power Units Chassis Liquid Cooled" Manual, Chapter "Line Modules / Active Line Modules" Motor Modules Motor Modules are power units (DC-AC inverter) that provide the power supply for the motor connected to them. Motor Modules are supplied with power via the DC link of the drive unit. You can find a description of the Motor Modules in the "SINAMICS S120 Power Units Chassis Liquid Cooled" Manual, Chapter "Motor Modules" Central Braking Module The Central Braking Module is used if the motors are operating in the generator mode, and it is not possible to feedback power into the line supply. The Central Braking Module then limits the DC link voltage at a central position in the drive line-up. You can find a description of the Central Braking Modules in the "SINAMICS S120 Cabinet Modules" Manual, Chapter, "Cabinet Modules / Central Braking Modules" Auxiliary Power Supply Modules The Auxiliary Power Supply Module supplies the following components: External loads Electronic modules You can find a description of the Auxiliary Power Supply Modules in the "SINAMICS S120 Cabinet Modules" Manual, Chapter, "Cabinet Modules / Auxiliary Power Supply Modules". 28 Operating Instructions, 04/2015, A5E A

29 Description 2.6 Description of the optional components Re-cooling unit The re-cooling unit supplies the liquid-cooled drive unit with cooling liquid. The re-cooling unit ensures sufficient coolant flow in the inner cooling circuit of the drive unit and for the exchange of heat with the outer cooling circuit of the re-cooling unit. For additional information, refer to the operating instructions of the re-cooling unit. 2.6 Description of the optional components AOP30 Advanced Operator Panel The "Advanced Operator Panel AOP30" operator panel it is an input/output device. The AOP30 is used for commissioning, operator control and diagnostics. The AOP30 communicates with the CU320-2 Control Unit via an RS232 serial interface using the PPI protocol. You can find a description of the AOP30 in the "SINAMICS S120 Cabinet Modules" Manual, Chapter "Options / K08, AOP30 Advanced Operator Panel" Output-side circuit-breaker The output-side circuit breaker disconnects the motor terminals from the converter. The output-side circuit breaker is installed in a separate cabinet. You can find a description of the circuit breaker in the "SINAMICS S120 Cabinet Modules" Manual, Chapter, "Options / L34, output-side circuit breaker" Operation in an IT supply system Surge arresters and upstream fuses are installed for each phase. The signaling contacts of the monitoring of the surge arresters and the fuses are connected in series and connected to a customer interface. You can find a description in the "SINAMICS S120 Cabinet Modules" Manual, Chapter, "Options / L21, operation on an IT supply system. Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 29

30 Description 2.6 Description of the optional components CBC10 Communication Board The "Communication board CBC10" module connects the drives of the SINAMICS drive system to higher-level automation systems with a CAN bus. The module is installed in the factory in the option slot of the CU320-2 Control Unit. You can find a description of the CBC10 in the "SINAMICS S120 Cabinet Modules" Manual, Chapter, "Options / G20, CBC10 communication board" CBE20 Communication Board The "Communication Board CBE20" interface module establishes the communication via PROFINET. The module is installed in the factory in the option slot of the CU320-2 Control Unit. You can find a description of the CBE20 in the "SINAMICS S120 Cabinet Modules" Manual, Chapter, "Options / G33, CBE20 communication board" Control Unit CU320-2 DP; Control Unit PN The CU320-2 Control Unit is a central control module. The CU320-2 is used for the open-loop and closed-loop control for one or several Line Modules and/or Motor Modules. You can find a description of the CU320-2 in the "SINAMICS S120 Cabinet Modules" manual, in Chapters "Options / K90, Control Unit CU320-2 DP and Options / K95, Control Unit CU320-2 PN". Performance enhancement The computing capacity requirement increases in proportion to the number of power units and system components and in relation to the dynamic response required. The full computing capacity of the CU320-2 Control Unit is available only with performance enhancement. In addition to the firmware, license keys are also saved on the CompactFlash card. The license keys are required to enable firmware options, e.g. performance enhancement and Safety Integrated Extended functions. 30 Operating Instructions, 04/2015, A5E A

31 Description 2.6 Description of the optional components dv/dt filter compact plus Voltage Peak Limiter The du/dt filter compact plus Voltage Peak Limiter consists of two components: The du/dt reactor The voltage limiting network (Voltage Peak Limiter). The voltage limiting network cuts-off the voltage peaks and feeds the energy back into the DC link. The "du/dt filter compact plus Voltage Peak Limiter" limits the voltage load on the motor cables to values in accordance with the limit value curve A in compliance with IEC/TS You can find a description of the du/dt filter in the "SINAMICS S120 Cabinet Modules" Manual, Chapter, "Options / L07, du/dt filter compact plus Voltage Peak Limiter" du/dt filter plus Voltage Peak Limiter The "du/dt filter plus Voltage Peak Limiter" consists of two components: The du/dt reactor The voltage limiting network (Voltage Peak Limiter). The voltage limiting network cuts-off the voltage peaks to the level of the DC link voltage and feeds the energy back into the DC link. The "du/dt filter plus Voltage Peak Limiter" limits the voltage rate of rise. You can find a description of the du/dt filter in the "SINAMICS S120 Cabinet Modules" Manual, Chapter, "Options / L10, du/dt filter compact plus Voltage Peak Limiter" EMC shield bus An EMC shield bus is incorporated for the use of shielded power cables for the line feeder and motor feeder cables. The cable shields for the cables routed to the cabinet must be connected to the EMC shield bus in accordance with EMC guidelines. You can find a description in the "SINAMICS S120 Cabinet Modules" Manual, Chapter, "Options / M70, EMC shield bus. Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 31

32 Description 2.6 Description of the optional components Grounding switch downstream of main breaker It is closed manually by means of a rotary actuator and ensures, for example, safe isolation from supply in the Cabinet Module during servicing. The grounding switch grounds the cabinet's internal components located downstream of the circuit breaker. You can find a description of the grounding switch in the "SINAMICS S120 Cabinet Modules" Manual, Chapter, "Options / L46/L47, grounding switch before/after the main switch" Grounding switch upstream of main breaker It is closed manually by means of a rotary actuator and ensures, for example, safe isolation from supply in the Cabinet Module during servicing. The grounding switch grounds the connected line feeder cables. You can find a description of the grounding switch in the "SINAMICS S120 Cabinet Modules" Manual, Chapter, "Options / L46/L47, grounding switch before/after the main switch" Holder for ARC detector You can attach ACR detectors of the arcing systems VA1DA1 / Vamp Ldt. company, as well as TVOC / ABB company. You can find a description of the holder in the "SINAMICS S120 Cabinet Modules" Manual, Chapter, "Options / L51, holder for ARC detector" Main contactor for Line Connection Modules < 800 A A Line Connection Module, adapted for connection to a Basic Line Module is equipped with a manually operated fuse load disconnector up to a rated current of 800 A. A contactor is required if a switching element is also required for disconnecting from the supply. The contactor is controlled by the connected Line Module. You can find a description of the main contactor in the "SINAMICS S120 Cabinet Modules" Manual, Chapter, "Options / L13, main contactor for Line Connection Modules < 800 A". 32 Operating Instructions, 04/2015, A5E A

33 Description 2.6 Description of the optional components Auxiliary power generation in the Line Connection Module Using this option, the auxiliary power is generated in the Line Connection Module. The following auxiliary voltages are available: 2 AC 380 up to 2 AC 480 V; 2 AC 500 up to 2 AC 690 V (possible tap depending on the Line Connection Module 35 A to 80 A) AC 230 V (possible tap, approx. 4 to 6 A) 24 V DC (possible tap, approx. 20 to 40 A) You can find a description in the "SINAMICS S120 Cabinet Modules" Manual, Chapter, "Options / K76, auxiliary power generation in the Line Connection Module" Insulation monitoring In non-grounded systems (IT systems), the insulation monitor checks the entire electricallyconnected circuit for insulation faults. The insulation resistance as well as all insulation faults from the line supply to the motors in the Cabinet Modules are detected. Two response values can be set (between 1 kω and 10 MΩ). If a response value is fallen below, an alarm is output at a terminal. A system fault is output via the signaling relay system. You can find a description of the insulation monitoring in the "SINAMICS S120 Cabinet Modules" Manual, Chapter, "Options / L87, insulation monitoring" Cable-marshaling compartment 200 mm high Because it is raised 200 mm, the cable marshaling compartment facilitates higher bending radii for cables (cable entry from below) and cable routing within the cable marshaling compartment. You can find a description of the cable marshaling compartment in the "SINAMICS S120 Cabinet Modules" Manual, Chapter, "Options / M07, cable marshaling compartment, 200 mm high, RAL 7035". Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 33

34 Description 2.6 Description of the optional components Circuit breaker in withdrawable unit design The circuit breaker in a withdrawable unit design replaces the circuit breaker installed as standard. The draw-out circuit breaker features a visible isolating distance. You can find a description of the circuit breaker in the "SINAMICS S120 Cabinet Modules" Manual, Chapter, "Options / L25, circuit breaker in a withdrawable unit design" Fan power supply The 1 AC 230 V and 24V DC voltages of the auxiliary power supply system are supplied externally from the plant/system. You can find a description in the "SINAMICS S120 Cabinet Modules" Manual, Chapter, "Options / K70, fan power supply" Measuring device for line supply variables The measuring device is installed in the cabinet door of the Line Connection Module. The measuring device senses power supply variables. In addition, other system values are calculated from the measured values, e.g. power, power factor and other values. The measuring device is equipped with a serial RS485 interface with JBUS/MODBUS, which supports a max. transmission rate of 38.4 kbaud. You can find a description in the "SINAMICS S120 Cabinet Modules" Manual, Chapter, "Options / P10, measuring device for line supply variables, mounted in the cabinet doors". 34 Operating Instructions, 04/2015, A5E A

35 Description 2.6 Description of the optional components Measuring device for line supply variables with PROFIBUS connection The measuring device is installed in the cabinet door of the Line Connection Module. The measuring device senses power supply variables. In addition, other system values are calculated from the measured values, e.g. power, power factor and other values. The measuring instrument has a PROFIBUS interface that enables a transfer rate of up to 12 Mbit/ s. You can find a description in the "SINAMICS S120 Cabinet Modules" Manual, Chapter, "Options / P11, measuring device for line supply variables with PROFIBUS interface, mounted in the cabinet door" Motor reactor Motor reactors reduce the voltage stress on the motor windings. This is achieved by reducing the voltage gradients at the motor terminals that occur when motors are fed from converters. At the same time, the capacitive charge/discharge currents that also occur on the output of the Motor Module when long motor cables are used are reduced. You can find a description of the motor reactor in the "SINAMICS S120 Cabinet Modules" Manual, Chapter, "Options / L08/L09, motor reactor/2 motor reactors in series" Line connection from above The cabinet unit has an additional canopy. The connection lugs for the power cables, the clamping bar for mechanically securing the cables, an EMC shield bus, and a PE busbar are located within the hood. You can find a description of the canopy in the "SINAMICS S120 Cabinet Modules" Manual, Chapter, "Options / M13, line connection from the top". Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 35

36 Description 2.6 Description of the optional components TM150 Temperature Sensor Module The TM150 Terminal Module is used to acquire and evaluate data from several temperature sensors. The temperature is sensed in a temperature range from -99 C up to +250 C. You can find a description of the TM150 in the "SINAMICS S120 Cabinet Modules" Manual, Chapter, "Options / G51 to G54, TM150 temperature sensor module" Terminal Module TM54F The TM54F Terminal Module is a terminal expansion module with safety-related digital inputs and digital outputs. The TM54F is used to control Safety Integrated functions. The TM54F provides 4 fail-safe digital outputs and 10 fail-safe digital inputs. A fail-safe digital output comprises the following inputs and outputs: An output that switches to 24 V DC An output that switches to ground A digital input to check the switched state. A fail-safe digital input comprises two digital inputs. You can find a description of the TM54F in the "SINAMICS S120 Cabinet Modules" Manual, Chapter, "Options / K87, TM54F Terminal Module" Safe Brake Adapter SBA 230 V AC The Safe Brake Adapter AC 230 V is used to control safe brake control (SBC). SBC is used in safety-related applications, e.g. presses and rolling mills. You can find a description of the Safe Brake Adapter in the "SINAMICS S120 Cabinet Modules" Manual, Chapter, "Options / K88, Safe Brake Adapter SBA AC 230 V". 36 Operating Instructions, 04/2015, A5E A

37 Description 2.6 Description of the optional components Closed cabinet door (air inlet from below through floor opening) The cabinet is equipped with doors without integrated ventilation meshes. Floor panel To ensure an adequate air-inlet cross-section, the units are shipped without the standard floor panels. WARNING Defective grounding straps Doors that are not grounded can be at a hazardous voltage. This can result in severe injury or death. It is not permissible that grounding straps, which are attached to the doors, are damaged when disassembling. When assembling, correctly and carefully connect the grounding straps to the doors. WARNING High voltage The converter has no floor panels. When touched, high voltages in the converter can result in severe injury or death. If it is possible to enter the area underneath the cabinet, it is essential that plant-side shock protection is provided for this area. CAUTION Dirt and moisture Dirt, conductive dust or moisture can result in material damage and as a consequence to converter failure. In this case, you must ensure that no dirt/conductive dust or moisture can enter the cabinet. Cables must not be routed in such a way that they impede the flow of air through the cabinet floor opening. CAUTION Non compliance with environmental conditions Overheating, drawing in dirt and pollution and the ingress of moisture can result in material damage and as a consequence to converter failure. Comply with the required environmental conditions to prevent, for example, overheating, drawing in dirt and pollution and the ingress of moisture into the cabinet. Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 37

38 Description 2.6 Description of the optional components Opening angle of the door The door opening angle with free-standing cabinet units is 180. The door opening angle when the cabinet units are lined up is 130. For degrees of protection IP23, IP43, IP54 and for DC coupling including pre-charging input circuit the door opening angle is IP21 degree of protection Additional drip plates are supplied to increase the degree of protection to IP21. This protection prevents vertically falling water drops from entering the cabinet. You can find a description in the "SINAMICS S120 Cabinet Modules" Manual, Chapter, "Options / M21, IP21 degree of protection" Degree of protection IP23 Additional drip plates and filter media are supplied to increase the degree of protection to IP23. This protection prevents the ingress of solid foreign bodies with diameters > 12.5 mm, and provides protection against spray water up to 60 with respect to the vertical. You can find a description in the "SINAMICS S120 Cabinet Modules" Manual, Chapter, "Options / M23/M43/M54, IP23/IP43/IP54 degree of protection" IP43 degree of protection Additional drip plates and filter media are supplied to increase the degree of protection to IP23. This protection prevents the ingress of solid foreign bodies with diameters > 1 mm, and provides protection against spray water up to 60 with respect to the vertical. You can find a description in the "SINAMICS S120 Cabinet Modules" Manual, Chapter, "Options / M23/M43/M54, IP23/IP43/IP54 degree of protection". 38 Operating Instructions, 04/2015, A5E A

39 Description 2.6 Description of the optional components IP54 degree of protection Additional drip plates and filter media are supplied to increase the degree of protection to IP23. This equipment provides the following protection: Complete shock protection Protection against damaging dust deposits Protection against splash water from all directions You can find a description in the "SINAMICS S120 Cabinet Modules" Manual, Chapter, "Options / M23/M43/M54, IP23/IP43/IP54 degree of protection" Contactor monitoring The contactor monitoring is used for monitoring the pre-charging and bypass contactors of the Line Modules. You can find a description of the contactor monitoring in the "SINAMICS S120 Cabinet Modules" Manual, Chapter, "Options / G56, contactor monitoring" SMC10 Sensor Module The "SMC10 Sensor Module Cabinet-Mounted" module is used to sense the actual motor speed and the rotor position angle. The signals received from the resolver are made available to the closed-loop controller via the DRIVE-CLiQ interface for evaluation purposes. You can connect the following encoders to the SMC10: 2-pole resolver Multi-pole resolver The motor temperature can also be sensed using KTY temperature sensors or PTC thermistors. You can find a description of the SMC10 in the "SINAMICS S120 Cabinet Modules" Manual, Chapter, "Options / K46, Sensor Module Cabinet-Mounted SMC10". Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 39

40 Description 2.6 Description of the optional components SMC20 Sensor Module The "SMC20 Sensor Module Cabinet-Mounted" module is used to sense the actual motor speed and the distance. The signals received from the incremental encoder are made available to the closed-loop controller via the DRIVE-CLiQ interface for evaluation purposes. You can connect the following encoders to the SMC20 encoder module: Incremental encoder sin/cos 1 V pp EnDat and SSI absolute encoders The motor temperature can also be sensed using KTY temperature sensors or PTC thermistors. You can find a description of the SMC20 in the "SINAMICS S120 Cabinet Modules" Manual, Chapter, "Options / K48, Sensor Module Cabinet-Mounted SMC20" SMC30 Sensor Module The "SMC30 Sensor Module Cabinet-Mounted" module is used to sense the actual motor speed. The signals received from the rotary pulse encoder are made available to the closedloop controller via the DRIVE-CLiQ interface for evaluation purposes. You can connect the following encoders to the SMC10: TTL encoders HTL encoders SSI encoders KTY or PTC temperature sensors You can find a description of the SMC10 in the "SINAMICS S120 Cabinet Modules" Manual, Chapter, "Options / K50, Sensor Module Cabinet-Mounted SMC30" SMC30 Sensor Module, additional The additional "SMC30 Sensor Module" enables safe actual value sensing when Safety Integrated Extended functions are used. You can find a description of the SMC30 in the "SINAMICS S120 Cabinet Modules" Manual, Chapter, "Options / K52, additional encoder module SMC30". 40 Operating Instructions, 04/2015, A5E A

41 Description 2.6 Description of the optional components Base 100 mm high Because it is raised 100 mm, the supplementary cabinet base allows for greater bending radii for cables (cable inlet from below) and cable routing within the base. You can find a description of the base in the "SINAMICS S120 Cabinet Modules" Manual, Chapter, "Options / M06, 100 mm high base, RAL 7022" Anti-condensation heating The anti-condensation heating is used at low ambient temperatures and high levels of humidity to prevent condensation from forming. You can find a description of the anti-condensation heating in the "SINAMICS S120 Cabinet Modules" Manual, Chapter, "Options / L55, cabinet anti-condensation heating" Current transformer upstream of the main switch The current transformers are used for measuring and monitoring purposes. For the Line Connection Modules, the current transformers are installed upstream of the main switch in all three line phases of the infeed. The current transformers have an accuracy class of 1.0. The secondary current is maximum of 1 A. You can find a description of the current transformers in the "SINAMICS S120 Cabinet Modules" Manual, Chapter, "Options / L41, current transformers upstream of the main switch" Voltage Sensing Module VSM10 The VSM10 Voltage Sensing Module allows the line supply or motor voltage characteristic to be precisely sensed. In addition, the VSM10 is used to switch to a rotating synchronous motor or for a quick flying restart of rotating induction motors (flying restart function). You can find a description of the VSM10 in the "SINAMICS S120 Cabinet Modules",Manual, Chapter "Options / K51, Voltage Sensing Module Cabinet-Mounted VSM10". Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 41

42 Description 2.6 Description of the optional components 42 Operating Instructions, 04/2015, A5E A

43 Preparations for use 3 Observe Chapter, "Safety instructions" when carrying out any work at the converter. 3.1 Requirements regarding the installation site The converter is designed for installation in closed electrical rooms in compliance with EN A closed electrical room contains electrical equipment. Only appropriately trained personnel may access these electrical rooms. These electrical rooms can only be accessed by opening a door or removing a barrier using either a key or appropriate tool. The room is clearly marked with the appropriate warning symbols. The installation location must be dry and dust-free. The air supplied must not contain any electrically conductive gas, vapors, or dust, which could impair operation. It may be necessary to filter the air supplied to the electrical room. If the air contains dust, filter mats can be installed in front of the ventilation meshes of the cabinet doors and also in front of the optional canopies. The canopy provides additional protection against water sprayed against the housing from any direction. The canopy corresponds to degree of protection IP54. The permissible values for climatic ambient conditions must be complied with. The units must be derated for ambient temperatures > 40 C (104 F) and installation altitudes > 2000 m. Derating data s regarding the derating data are provided in the "SINAMICS S120 Cabinet Modules" Manual, Chapter, "System overview/derating data". The basic version of the cabinet units complies with the IP20 degree of protection in accordance with EN Requirements for IP20 The units only satisfy the requirements to achieve IP20 after the righthand side and lefthand side panels have been attached. The units must be mounted and installed corresponding to the dimension drawings provided. The clearance to be maintained between the top of the cabinet and the ceiling is shown in the diagram below. Additional dimensions must be taken into account if the unit has a base or cable marshaling space. Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 43

44 Preparations for use 3.1 Requirements regarding the installation site A B C Basic version, IP20 Offset roof panel, drip plate, IP21 Doors and canopy with protective mesh and filter mat, IP23 / IP34 / IP54 Minimum ceiling height in mm Ventilation mesh and filter mats Variable air discharge area Air inlet area Cabinet height in mm Figure 3-1 Required room height for different degrees of protection without a base and cable marshaling space Further dimensions Further dimensions can be found in the relevant dimension drawings on the customer DVD supplied with the device. The cooling air for the power unit is drawn in from the front through the ventilation grilles in the lower part of the cabinet doors. The warmed air is expelled through the perforated roof panel or the ventilation mesh into the canopy. Cooling air can also be supplied from below through 44 Operating Instructions, 04/2015, A5E A

45 Preparations for use 3.2 Inspections when the equipment is received raised floors or air ducts, for example. To allow this, openings must be made in the sectioned floor panel. Interference to wireless services caused by high-frequency disturbances in residential environments This product can cause high-frequency interference in a residential environment that can require radio interference suppression measures. This unit is not designed for operation in the first environment (residential environment). It is not permissible that the unit is used in the first environment without applying suitable noise/ interference suppressing measures. Have the installation and commissioning with appropriate radio interference suppression measures preformed by qualified personnel. 3.2 Inspections when the equipment is received Checking the delivery The components are assembled on an individual basis. When you take receipt of the delivery, please check immediately whether the scope of the delivery matches up with the accompanying documents. No claims relating to defects/items missing from the delivery will be accepted if they are submitted at a later date. Report any apparent transport damage to the delivery agent immediately. Immediately report any apparent defects/missing components to your contact partner. These Operating Instructions are part of the scope of delivery; keep them in a location where they can be easily accessed. Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 45

46 Preparations for use 3.2 Inspections when the equipment is received Checking shock and tilt indicators The purpose of shock and tilt indicators The 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 also Siemens Industry Online Support (Page 139) 46 Operating Instructions, 04/2015, A5E A

47 Preparations for use 3.2 Inspections when the equipment is received Location of the indicators You can find the indicators at the following locations: The tilt indicators are located in the upper third of the cabinet. The shock indicators are located at the bottom of the cabinet. 1 2 Tilt indicator Shock indicator Figure 3-2 Example for attaching shock and tilt indicators Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 47

48 Preparations for use 3.2 Inspections when the equipment is received Diagram showing the indicators Non-tripped indicator 1 2 The arrow above the line is white. The tilt indicator has not tripped. All arrows are red. The shock indicator has not tripped. Tripped indicator 1 2 The arrow above the line is blue. The tilt indicator has tripped. One of the arrows has turned black. The shock indicator has tripped. 48 Operating Instructions, 04/2015, A5E A

49 Preparations for use 3.3 Transport Checking the load handling attachments Check 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 The device may fall 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. 3.3 Transport 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 Transport markings The 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). Comply with the images shown on the packaging. Their meaning is as follows: This way up Fragile goods Keep dry Keep cool Center of gravity Do not use hand hook Attach here Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 49

50 Preparations for use 3.3 Transport 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 /2/3. Please also observe the "Technical specifications" instructions. When lifting the drive, use only approved and undamaged sling guides and spreaders of sufficient rated capacity. Check these before using them. The weight of the drive is specified on the rating plate. NOTICE Vibrations Significant vibration during transportation and shocks when setting down can damage the equipment. Avoid vibrations and shocks Take the center of gravity into account 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 3-3 Example illustration of centers of gravity 50 Operating Instructions, 04/2015, A5E A

51 Preparations for use 3.3 Transport Transport with a fork-lift truck WARNING Use of non-approved fork-lift trucks 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 Transporting using a crane WARNING Improper 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 Standing under suspended loads If the lifting gear or load suspension devices were to fail, the transport unit/cabinet could fall. This can result in death, serious injury or material damage. Do not stand underneath or near to a raised load. Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 51

52 Preparations for use 3.3 Transport Observe the following points for safe transport: When using a crane to transport the equipment, keep to the permissible lifting capacity. Carefully observe the center of gravity. If the cabinet center of gravity is off-center, use suitable and undamaged suspension equipment, e.g. a cross beam. The lifting beam reduces the pressure on the device and prevents damage. If the cabinet has eye hooks, use them. In such cases, do not use any lifting rods. Transport using the top-mounted eye bolts Figure 3-4 Diagram: crane transportation Attach the crane to the top-mounted lifting eyebolts and then lift the cabinet. Avoid displacing the center of gravity or distorting the cabinet. When suspended, the cabinet must be parallel to the ground. 52 Operating Instructions, 04/2015, A5E A

53 Preparations for use 3.3 Transport With systematic loading, the total permissible loads specified below apply: With 45 Bowden cable bracket With 60 Bowden cable bracket With 90 Bowden cable bracket 4800 N 6400 N N The center of gravity of the cabinet is specified in the dimension drawing. The load carrying capacity of the hoisting gear must be adequate for the weight specified in the dimension drawing. Transport using lifting rails WARNING Inadequately dimensioned lifting rods Inadequately dimensioned lifting rods are liable to bend or break. The drive could drop off 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. If the cabinets/transport units are equipped with lifting rails, then proceed as follows: 1. If there are several holes, select which holes to use based on the center of gravity. 2. Push the lifting rods through the holes. 3. Place the sling ropes on the lifting rods so they are close to the cabinet. Secure the ends of the lifting rods using the splint. Figure 3-5 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. Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 53

54 Preparations for use 3.3 Transport Transporting transportation units packed in boxes Transportation with the fork-lift truck When the transport units are transported with a fork-lift truck, the force is absorbed through the transport pallet. Observe the guidelines described in the section "Transport with a fork-lift truck". Transportation with the crane Observe the guidelines described in the section "Transport with a crane". 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 Carefully raise the transportation unit Spreader beam Center of gravity Imprinted position of the rope Figure 3-6 Transporting a transportation unit (still in packaging) with a crane See also Transporting using a crane (Page 51) Transport with a fork-lift truck (Page 51) 54 Operating Instructions, 04/2015, A5E A

55 Preparations for use 3.3 Transport Disassembling the crane transport assembly The cabinet are equipped either with transport eyebolts of lifting rails. Unscrew the crane eyebolts or remove the lifting rails. 1. Depending on the length of the cabinet or the transport unit, the lifting rails are attached with a different number of screws. Release the screws to remove the lifting rails. WARNING Lifting rails can fall down The lifting rails are heavy. If the lifting rails fall down, they can cause injury or material damage. Very carefully remove the lifting rails from the cabinet. NOTICE Screws in the converter Screws can fall into the unit as it is disassembled and cause serious damage when the equipment is started up. After removing the lifting rails, check as to whether all of the screws are available. Remove any screws that have fallen into the converter. Figure 3-7 Lifting rails 2. After removing the transport eyebolts or the screws from the lifting rails, replace them with the screws from the accessories pack. Only use the screws provided in order to maintain the degree of protection and to ensure that the cabinet is correctly grounded. Figure 3-8 Fixing screws Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 55

56 Preparations for use 3.4 Unpacking the cabinets 3.4 Unpacking the cabinets 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. Refer to the storage information under "Storage" and in the section "Technical specifications". Remove the packaging immediately prior to installation. The devices are packaged by the manufacturers in accordance with the order and the climatic conditions of the transport route in the receiving country. 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 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. 56 Operating Instructions, 04/2015, A5E A

57 Preparations for use 3.4 Unpacking the cabinets 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 Lifting the cabinet units off the transport pallet and installing them You can remove the screws that attach the unit to the transport pallets without having to lift the cabinet unit. Red marks indicate the positions of the fixing screws Fixing screws for units without base Fixing screws for units with base Cover Figure 3-9 Transport pallet screws Proceed as follows to release and remove the fixing screws: For cabinet units without base 1, release the fixing screws from the lower side of the transport pallet. For cabinet units with base 2, open cover 3 and then release the screws from the front. See also Take the center of gravity into account (Page 50) 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 "Check shock and tilt indicators" Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 57

58 Preparations for use 3.5 Storage See also Checking shock and tilt indicators (Page 46) 3.5 Storage NOTICE Formation of condensation with open transport packaging If the transport packaging is open and the auxiliary power is not connected for heating operation or normal operation, condensation can form which can damage the unit. Store the inverter in its transport packaging Emptying the drive NOTICE Unemptied cooling system The coolant can corrode the components over the long term. Coolant can also freeze at temperatures of below 0 C causing damage to the drive. Make sure that the coolant has been completely removed from the system before the device is placed in storage. If the drive is stored for a longer period of time, then close and seal all water intakes and discharge points to protect against vermin and dirt. If the drive was already connected to the cooling system and you want to store the drive away again, empty the drive completely prior to storing. To empty the drive proceed as follows: 1. Open the connection between the cabinet piping and the external piping. 2. Drain the coolant. 3. Then tighten the screws again. 4. At one of the flanges of the cabinet piping, connect oil-free compressed air or a nitrogen bottle. Use a suitable transition element. Blow out any residual water. NOTICE Blow-out pressure too high If the blow-out pressure used exceeds 6 bar, the piping and the heat sink can become damaged. Do not exceed the blowout pressure of 6 bar. Avoid pressure surges. 58 Operating Instructions, 04/2015, A5E A

59 Preparations for use 3.5 Storage Storing a device If 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 storage Wherever 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 (v eff 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 (50 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. Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 59

60 Preparations for use 3.5 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 Forming DC link capacitors If the Basic Line Modules, Active Line Modules, and Motor Modules have not been used for more than two years, then you must reform the DC link capacitors. If you do not reform the capacitors, the units could be damaged after the DC link voltage is applied under load. If the units are commissioned within two years of their date of manufacture, the DC link capacitors do not need to be reformed. The date of manufacture is coded in the serial number on the rating plate. You can find a description of how to form the DC link capacitors in the "SINAMICS S120 Cabinet Modules" Manual, Chapter, "Maintenance and service". 60 Operating Instructions, 04/2015, A5E A

61 Preparations for use 3.5 Storage Storing re-cooling units Coolant CAUTION The coolant is harmful to eyes and skin and can damage surfaces. Therefore, wear appropriate protective clothing for all work on the converter. However, if your eyes or skin do come into contact with coolant, rinse the affected area thoroughly with tap water as soon as possible. If coolant leaks, eliminate the source of the problem and remove the liquid from the surfaces affected. WARNING Live, moving or rotating parts Contact with the parts mentioned can result in death, serious physical injury or damage to property. Before you drain the cooling unit, ensure that the pumps are stationary and the power has been disconnected. Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 61

62 Preparations for use 3.5 Storage Draining the cooling circuit 1. Connect the attached ½ " hose with valve at the discharge connections at the end of the coolant pipes. 1 ½ " hose 2 Container for the cooling water that has drained Figure 3-10 Draining the cooling circuit 2. Inject nitrogen into the cooling unit through filling valve 3 to force out the coolant. It is not permissible that the nitrogen pressure exceeds 6 bar, in order that the cooling unit is not damaged. 3 Filling valve Industrial compressed air contains oil and is therefore not suitable. If you use normal compressed air it must be 100% dry. 62 Operating Instructions, 04/2015, A5E A

63 Preparations for use 3.5 Storage If the cooling unit is not used for longer periods of time, there is a risk that parts of the system will be clogged up with ethylene glycol. If the cooling unit is not used after it has been drained for a longer period of time, then we recommend that the system is flushed using clean water, e.g. municipal water. This flushes out coolant deposits. To prevent oxidation, all water residues must be removed and the plant must be dry. Therefore, after flushing, empty the system using nitrogen. Disposal Dispose of the equipment-water mixture and the water used for flushing, taking into account local regulations. Reuse is preferred over disposal. Please refer to the disposal notes of the coolant manufacturer. Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 63

64 Preparations for use 3.5 Storage 64 Operating Instructions, 04/2015, A5E A

65 Installation 4 Before mounting and installation, complete the checklist for the mechanical installation (Page 145) 4.1 Safety instructions for assembly Observe Chapter, "Safety instructions" when carrying out any work at the converter. NOTICE Improper installation The 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. Protect the drive against excessive stress and loading. WARNING Danger as a result of defective seals When working on the device, seals at the doors, roof panels as well as front, rear and side panels can be damaged. Operating the device 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 specifications. WARNING Insufficient degree of protection from dust deposits Dust gets deposited in the drive during installation work. Dust deposits can lead to the drive no longer fulfilling the requirements of the degree of protection indicated. If the drive is operated with an insufficient degree of protection, death, serious injury, and material damage can result. Therefore, remove dust 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. Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 65

66 Installation 4.3 Torques NOTICE Foreign bodies in the drive If, after installation and maintenance work, foreign bodies are left in the drive, this can damage it when switching on. Before switching on, check as to whether there are any foreign bodies in the drive. Remove any foreign bodies. 4.2 Tools required You will need the following tools: Standard set of tools with screwdrivers, screw wrenches, socket wrenches, etc. Torque wrenches from 1.5 Nm up to 100 Nm 600 mm extension for socket wrenches 4.3 Torques The following tightening torques apply when tightening current-conducting connections, e.g. DC-link connections, motor connections, busbars, lugs and other connections (for example ground connections, protective conductor connections, steel threaded connections/glands). Table 4-1 Tightening torques for screw connections Thread Ground connections, protective conductor connections, steel threaded connections Aluminum threaded connections, plastic, busbars, lugs M3 1.3 Nm 0.8 Nm M4 3 Nm 1.8 Nm M5 6 Nm 3 Nm M6 10 Nm 6 Nm M8 25 Nm 13 Nm M10 50 Nm 25 Nm M12 88 Nm 50 Nm M Nm 115 Nm NOTICE Screw connections for protective covers The screw connections for the protective covers made of Makrolon may only be tightened with 2.5 Nm. 66 Operating Instructions, 04/2015, A5E A

67 Installation 4.5 Connections of transport units 4.4 Connecting to the foundation Preparatory steps If possible, allow unimpeded access to the holes at the bottom of the cabinet units by removing the protective covers when carrying out installation work. Connection to the foundation Four holes for M12 screws are provided on each cabinet panel to secure the cabinet to the foundation. The fixing dimensions are specified on the associated dimension drawings. Every cabinet panel must be attached to the ground using at least two opposing attachment points (one screw each in the front and rear part of the cabinet panel). If this is not possible for reasons of accessibility, then the attachment points of the adjacent cabinet panels must be correspondingly raised. Generally, as many attachment points as possible should be used. Additional information Further dimensions can be found in the relevant dimension drawings on the customer DVD supplied with the device. 4.5 Connections of transport units Connecting the collecting pipes of the cooling circuit If several transport units are lined-up to create a complete system, then as first step, you must connect the collecting pipes of the cooling circuit. The collecting pipes are located at the rear lower cabinet area. The collecting pipes are supplied as supplementary pack for connecting the transport units. Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 67

68 Installation 4.5 Connections of transport units 1 2 Pipe coupling Pipe ends 1. Position the first transport unit at the intended location. 2. Remove the protective caps. 3. Push the pipe couplings 1 provided loosely over the ends of the collecting pipes Position the next transport unit in the line-up at the intended location. Carefully insert the ends of the pipes into the protruding pipe couplings. Ensure that the cabinets are completely lined up and are at the same level. This may require leveling, example, using shims. Ensure that the water pipes line up axially. 5. Push the pipe couplings over the pipe joints. 6. Tighten the hexagon socket-head screw 1 with the torque specified on the pipe coupling. 1 Hexagon socket-head screw of the pipe coupling Connecting the converter system with the cooling unit Connect the collecting pipes of the system to the cooling unit. Proceed in the same way as described in Section "Connecting collecting pipes of the cooling circuit". 68 Operating Instructions, 04/2015, A5E A

69 Installation 4.5 Connections of transport units To do this, use the pipe couplings that are also provided. Observe the supply and return pipes of the cooling circuit The rear pipe of the supply of the cooling circuit and the front pipe of the return of the cooling circuit are located in the converter cabinet. Always observe the information in the operating instructions of the cooling unit Connecting cabinets Each cabinet unit and/or each transport unit has an accessories pack. The contents of this accessories pack comprises the following parts: 1 sealing tape 3 outer cabinet connectors with screws 3 inner cabinet connectors with screws Connecting the cabinets and/or transport units 1. Glue the sealing tape to the cabinet cross-beams of the cabinets to be connected. 2. Move the cabinets together with a clearance of approx. 3 mm between them. 3. Attach the inner cabinet connectors with four of the screws provided. Comply with the tightening torque specified. The position of the cabinet connectors is shown in the following diagrams. 4. Attach the outer cabinet connectors with two of the screws provided. Comply with the tightening torque specified. The position of the cabinet connectors is shown in the following diagrams. 5. If, before assembling, you removed the protective covers and doors, then reattach the protective covers and doors. Also attach the grounding connections to the doors. Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 69

70 Installation 4.5 Connections of transport units 1 Inner cabinet connector 2 Outer cabinet connector Figure 4-1 Overview of the position of the cabinet connectors Cabinet clearance, 3 mm Inner cabinet connector, lower; tightening torque 5 Nm Inner cabinet connector, upper; tightening torque 5 Nm Outer cabinet connector; tightening torque 9 Nm Figure 4-2 Cabinet connectors Installing the canopy or hood at an early stage In order to prevent the ingress of foreign bodies into the unit, attach the drip plate or canopy at an early stage. 70 Operating Instructions, 04/2015, A5E A

71 Installation 4.5 Connections of transport units Installing the side panels You must attach a side panel to the left and right of each cabinet line up that you install Connecting the DC and PE busbars Connecting the DC busbar The DC busbar is used to couple the DC link of the Basic Line Modules or Active Line Modules with the Motor Modules. The DC links of the modules are connected with different current carrying capacities using prefabricated sets of busbars. The busbars run horizontally through the upper section of the cabinets. Jumpers connect the DC busbars between several transport units. The jumpers are already loosely attached at the right-hand end of the DC busbar. 1. Loosen the two M12 nuts on the rear DC busbar (DC P) on the right-hand side of the first cabinet. 2. Loosen the two M12 nuts on the rear DC busbar on the left-hand side of the second cabinet. NOTICE Damage to the unit If you release the screws instead of just loosening them, the screws can fall into the unit. This can damage the unit. Only loosen the retaining screws. Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 71

72 Installation 4.5 Connections of transport units 3. Remove jumper 1 from the DC busbar of the first cabinet. Push the jumper up to the end stop in the DC busbar of the second cabinet. 1 Jumper Figure 4-3 Connecting the DC busbar when cabinet units are installed side-by-side 4. Tighten the nuts of the DC busbar in both cabinet units with a torque of 50 Nm. NOTICE Damage to the unit The temperature of the contacts can become inadmissibly high if this torque is not complied with. This can damage the unit. Comply with the torque of 50 Nm. 5. Repeat steps 1 to 4 for the front DC busbar (DC N). You must attach a side panel to the left and right of each cabinet line up that you install. Before mounting the side panels onto an installed cabinet line up, you must remove any jumpers present in the DC busbars of the cabinet to the right! 72 Operating Instructions, 04/2015, A5E A

73 Installation 4.5 Connections of transport units Connecting the PE busbar A connecting jumper for the PE busbar is supplied with every cabinet. The installation of the transport units as well as the connection of the transport units with each other must have been completed. Establishing the connection Nut M12 Connecting jumper Screw with washer Figure 4-4 Connecting the PE busbar 1. Allow unimpeded access to the PE busbars in the cabinet units. If required, remove the protective covers while carrying out any installation work. 2. Release the M12 nut 1 of the PE busbar at the first cabinet. 3. Remove the nut 1, the washer and the screw Release the M12 nut of the PE busbar at the second cabinet. 5. Remove the nut, washer and screw. 6. Place the connection jumper 2 at the rear of the PE busbars of the cabinets to be connected. 7. Insert the screws from the front into the grounding lugs of the PE busbar. 8. Reattach the washers and nuts. 9. Tighten the nut with a torque of 50 Nm. See also Connecting to the foundation (Page 67) Connecting cabinets (Page 69) Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 73

74 Installation 4.5 Connections of transport units Connecting-up according to the plant-side grounding concept WARNING Danger to life due to electric shock when not grounded If there is no connection to the central grounding of the complete plant, the cabinet unit may be at a dangerous voltage level in a fault situation. This means that when touched, this can result in death or severe injury Ground the device in compliance with the applicable regulations Connecting cables brought out to the PE busbar Establishing the connection 1. Insert the screw from the front. 2. Attach the cable lug from the rear. 3. Attach the nut and, if necessary, the washers and tighten (tightening torque: 50 Nm). Close the cabinet doors When external cables that are to be connected to the PE busbar have been laid, make sure that the cabinet doors close properly. 74 Operating Instructions, 04/2015, A5E A

75 Electrical connection 5 Before mounting and installation, complete the checklist for the electrical installation (Page 146) 5.1 Safety instructions for electrical connections Observe Chapter, "Safety instructions" when carrying out any work at the converter. WARNING Insufficient degree of protection as a result of modifying the floor/roof panel If you make any changes to the floor panel or the roof panel in order to modify the cable entry, the changes may result in the drive no longer meeting the requirements for the degree of protection shown. If there are holes in the floor or roof panel, then animals and vermin, for example, can get into drive during operation. If the drive is operated with an insufficient degree of protection, death, serious injury, and material damage can result. To maintain the drive's degree of protection, seal the holes so they are air-tight immediately after installation. WARNING Danger as a result of defective seals When working on the device, seals at the doors, roof panels as well as front, rear and side panels can be damaged. Operating the device 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 specifications. Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 75

76 Electrical connection 5.1 Safety instructions for electrical connections WARNING Short-circuits Damaged 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. NOTICE Using magnetic parts The use of magnetic parts (e.g. magnetic cable clamps) is not permitted. Using magnetic parts can damage the drive. Only use parts that consist of non-magnetic material. NOTICE Improper shrinking of 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. 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. We recommend using shielded cables. Unshielded cables can transfer disturbances to the control and signal lines and lead to malfunctions in the drive. 76 Operating Instructions, 04/2015, A5E A

77 Electrical connection 5.2 Electromagnetic compatibility 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. See also Electromagnetic compatibility (Page 77) 5.2 Electromagnetic compatibility The following fundamental information and guidelines facilitate compliance with the EMC directives. 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). 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 electric power cable and signal cable should be > 20 cm. The drive-specific information applies to 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. Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 77

78 Electrical connection 5.2 Electromagnetic compatibility 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 VDC Unshielded cables for 25 VAC Shielded analog signal cables Shielded bus and data cables Operator panel interfaces, incremental/absolute encoder cables Class 2: Unshielded cables for > 60 VDC and 230 VDC Unshielded cables for > 25 VAC and 230 VAC Class 3: Unshielded cables for > 230 VAC/VDC and 1000 VAC/DC Class 4: Unshielded cables for > 1000 VAC/DC Shield connection Do not use cable shields to conduct current. In other words, cable shields must not simultaneously act as neutral or PE conductors. 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 via a wire. This reduces the shield effectiveness by up to 90%. 78 Operating Instructions, 04/2015, A5E A

79 Electrical connection 5.2 Electromagnetic compatibility Attach the cable shield to a shield bar directly after the line inlet into the cabinet. Insulate the shielded cable without any interruptions. Route the cable shield up to the device connection Shielding bus Shielded cable Mounting clip Figure 5-1 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 Shield buses Cable Terminals Figure 5-2 Bridging shield gaps Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 79

80 Electrical connection 5.3 Connection I/O interfacing 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. The operating coils for contactors and relays in the drive must be connected to overvoltage limiters (e.g. RC elements or varistors). In order to reduce noise/interference entering or exiting via the cable, filter auxiliary voltages in the control cabinet. 5.3 Connection Preparations for connecting the power cables Disconnect the cabinets from the power supply. Ensure that all the necessary safety measures have been taken at the installation location. Allow unimpeded access to the cable clamping bar in the cabinets. 80 Operating Instructions, 04/2015, A5E A

81 Electrical connection 5.3 Connection Connecting the motor cable A B Frame sizes FX, GX, HX Frame size JX Figure 5-3 Connecting the motor cables 1. Open the cabinet. Removed the covers in front of the connection panel for the motor cables (connections U2/T1, V2/T2, W2/T3; X2). 2. Move or remove the base plate below the connection panel through which the motor cables are fed. 3. Attach the PE protective conductor at the intended locations in the cabinet to the appropriate connection with the ground symbol. Observe the torque of 50 Nm for M12. Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 81

82 Electrical connection 5.3 Connection 4. Screw the motor cables onto the terminals. Connect the conductors in the following sequence: U2/T1, V2/T2, W2/T3! Frame size max. cable cross-section mm 2 FXL 2 x 95 GXL 2 x 240 HXL 4 x 185 JXL NOTICE Busbar Danger of thermal destruction Cables that have not been properly secured at the connection point, represent a high electrical transition resistance, which can result in thermal destruction (contact corrosion). Tighten the M12 screws with the appropriate torque of 50 Nm. 5. To avoid placing mechanical strain on the terminals, connect the motor cables to the cable retaining rail. 6. When shielded motor cables are used, the shields must be secured to the EMC shield bus in an EMC-compliant manner. For the position of the connections for motor cables, see the layout diagrams included on the supplied customer CD. Route the motor grounding cable directly to the cabinet. Connect the motor grounding cable to the PE busbar. Direction of motor rotation Connect three-phase induction motors with a clockwise phase sequence (when viewing the drive shaft) to the converter as follows: Table 5-1 Converter and motor connection terminals Converter (motor connection terminals) U2/T1 V2/T2 W2/T3 Motor (connection terminals) U V W For a counterclockwise rotating field (when viewing the drive shaft), interchange two phases with respect to a clockwise rotating field. 82 Operating Instructions, 04/2015, A5E A

83 Electrical connection 5.3 Connection If an incorrect phase sequence was connected during the cable installation and it cannot be corrected by a subsequent swapping of the motor cables, you have two possibilities: Change the phase sequence by entering a negative setpoint. Change the phase sequence with the drive parameterization. Interconnect the windings for motors that can be operated in star-delta correctly. To do this, read the motor documentation. Observe the required isolation voltage for the operation of the drive Line/power connections Line Connection Modules Table 5-2 Line/power connection of the Line Connection Modules Terminals U1/L1, V1/L2, W1/L3 3-ph. AC power input Technical specifications Voltage: 380 V AC, 3-phase 10% to 480 V AC, 3-phase +10% (-15% < 1 min) 500 V AC, 3-phase 10% to 690 V AC, 3-phase +10% (-15% < 1 min) Connecting thread: M12/50 Nm or M16/115 Nm for ring cable lugs in accordance with DIN Motor Modules in chassis format Table 5-3 DC link / motor connection of the Motor Modules Terminals DCP, DCN DC power input U2/T1, V2/T2, W2/T3 3-ph. AC power output Technical specifications Voltage: 510 to 750 VDC 675 to 1035 VDC Voltage: 0 V 3-ph. AC to 0.72 x DC link voltage Connection: M12/50 Nm or M16/115 Nm for ring cable lugs in accordance with DIN Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 83

84 Electrical connection 5.3 Connection Connecting the ground Each cabinet contains a PE busbar for grounding the components installed in the cabinet. The nickel-plated busbars is located in the lower section of the cabinet and is secured at the left and right to the ground straps in the cabinet. Close the cabinet doors When ground connections are connected to the PE busbar, it must be ensured that the cabinet doors can still be closed Connection according to the system-side grounding concept WARNING Electric shock if there is no ground connection If there is no connection to the central grounding of the complete plant, the cabinet unit may be at a dangerous voltage level in a fault situation. This means that when touched, this can result in death or severe injury. Ground the device in compliance with the applicable regulations Connecting external cables to the PE busbar Establishing the connection 1. Insert the screw from the front. 2. Attach the cable lug from the rear. 3. Attach the nut and, if necessary, the washers and tighten (tightening torque: 50 Nm). Close the cabinet doors When external cables that are to be connected to the PE busbar have been laid, make sure that the cabinet doors close properly. 84 Operating Instructions, 04/2015, A5E A

85 Electrical connection 5.3 Connection Operation on an isolated line supply (IT supply system) Deactivate the integrated EMC filter when connected to an isolated line supply (IT supply system). To do this, unscrew and remove the connecting clip in the following Cabinet Applications: Basic Line Module Active Line Module (connecting clip in the Active Interface Module) You can find the position of the connecting clip in the interface overviews in the "Manual S120 Power Units Chassis Liquid Cooled" on the customer CD provided. NOTICE Damage to the unit Failing to remove the connecting clip to the EMC filter when connected to an isolated line supply / IT supply system can cause significant damage to the unit. Removing the connecting clip Signal connections Pre-assignment and position of the customer terminal block The factory setting and description of the customer terminal blocks are documented in the circuit diagrams. The location of the customer terminal blocks of the individual Cabinet Modules is documented in the layout diagrams. The interfaces or customer terminal blocks are documented for the respective Cabinet Modules. DRIVE-CLiQ cables must be locally routed according to the customer-specific engineering specifications for the entire system Other connections Depending on the optional components installed, you have to connect additional connections. Information about the interfaces of the possibly available options is provided in the relevant sections of these operating instructions. Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 85

86 Electrical connection 5.4 Cable routing Fastening the cable ducts with cable ties Fasten 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 5-4 Fastening the cable ties 5.4 Cable routing Basic rules for cable routing DANGER Hazardous electrical voltage The work described in this section is carried out in cabinets that are operated in industrial high-voltage installations. During operation, this cabinet contains live parts at high voltages and rotating parts. Fatal or severe injuries and substantial material damage can occur if the required covers are inadmissibly removed or when incorrectly used, incorrectly operated or inadequately maintained. Read and observe the safety and application notes. Ensure, before starting work for all cable routing and connection work in the Cabinet Applications the following: Bring the cabinet unit into a no-voltage condition. Comply with the "five safety rules". Facilitate free access to the required components in the Cabinet Modules. If necessary, remove the covers. 86 Operating Instructions, 04/2015, A5E A

87 Electrical connection 5.4 Cable routing The Cabinet Applications are to a large extent supplied completely wired up. Comply with the following basic rules when carrying out any necessary wiring and cable routing/connection work. Observe the EMC directives. Uses the existing paths of the prefabricated cables. Use the existing shield plates. Do not bypass the shield plates. When required, use the existing cable retaining rails. Attach cable ties at suitable points on metal frames and cabinet frame profiles. Use the cabinet frame for routing to adjacent cabinets. Do not route cables in areas where condensation can form, e.g. on water pipes. Reattach any covers removed during cable routing before completing the work and commissioning Safety and EMC DANGER Hazardous electrical voltage Live parts can be touched if covers are not remounted. When touched, this can result in death or serious injury. Reattach all covers removed to route cables before you commission the unit. In order to achieve EMC-compliant shielding, before commissioning the unit, reattach the shield plates. Attach the shields of the motor cables to the optional EMC shield bus. Attach the PE conductors to the PE busbar. When routing cables, do not change any of the wiring inside the cabinet Cable routing for Basic Line Modules Comply with the basic rules for cable routing (Page 86) when carrying out all cable routing and connection work. Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 87

88 Electrical connection 5.4 Cable routing Route the following cables or carry out the following connection work: Table 5-4 Checklist for cable routing and connection work Cable routing PROFIBUS cable or PROFINET cable to the Control Unit DRIVE-CLiQ connections / signal cables to the Control Unit Signal cables to the customer terminal block X55 Completed? Cable routing for PROFIBUS or PROFINET connections to the Control Unit 1. Route the cable for the Control Unit from the bottom left in the cabinet. 2. Remove approximately 3 cm cable insulation from the cable at the height of the shield plate in the lower section of the cabinet. Attach the cable to the shield plate. 3. Attach the cable by snapping the retaining clamp into the shield plate in an EMC-compliant fashion. 4. Use cable ties to secure the cable at appropriate locations. 5. Feed the cable up through the cabinet and, at the height of the Control Unit, route it directly up and to the right towards the Control Unit. Route the cable corresponding to the standard cable prerouted in the cabinet. 6. Use cable ties to secure the cable at appropriate locations. 7. Connect the cable to the Control Unit. Information regarding connecting the cable is provided in the "Control cabinets and supplementary system components" manual Cable routing for DRIVE-CLiQ connections and signal cables 1. Route the DRIVE-CLiQ/signal cable from the bottom left in the cabinet. 2. Use cable ties to secure the cable at appropriate locations. 3. Feed the cable up through the cabinet and, at the height of the Control Unit, route it directly up and to the right towards the Control Unit. Route the cable corresponding to the standard cable prerouted in the cabinet. 4. Use cable ties to secure the cable at appropriate locations. 5. Connect the DRIVE-CLiQ/signal cable to the Control Unit Cable routing to the customer terminal block -X55 1. Route the cable for the customer terminal block from the bottom left in the cabinet. 2. Remove approximately 3 cm cable insulation from the cable at the height of the shield plate in the lower section of the cabinet. Attach the cable to the shield plate. 3. Attach the cable by snapping the retaining clamp into the shield plate in an EMC-compliant fashion. 4. Use cable ties to secure the cable at appropriate locations. 88 Operating Instructions, 04/2015, A5E A

89 Electrical connection 5.4 Cable routing 5. Guide the cable further up into the cabinet and, when it reaches customer terminal block - X55, guide it to the left or right to -X55. Route the cable corresponding to the standard cable prerouted in the cabinet. 6. Use cable ties to secure the cable at appropriate locations. 7. Connect the cables to the customer terminal block X55. Optional interface -X55 You can find notes regarding the optional X-55 interface in the "SINAMICS S120 Cabinet Modules" Manual, in Chapter "Interface description" Cable routing for Motor Modules Comply with the basic rules for cable routing (Page 86) when carrying out all cable routing and connection work. Route the following cables or carry out the following connection work: Table 5-5 Checklist for cable routing or connection work for Motor Modules Cable routing PROFIBUS cable or PROFINET cable to the Control Unit DRIVE-CLiQ connections / signal cables to the Control Unit Signal cables to the customer terminal block X55 Terminal Module TM54F (optional) Safe Brake Adapter SBA 230 V AC (optional) Signal cables to Sensor Module SMC10/20/30 ( B81/ B82/ B83) Cable connection between motor and Motor Module Completed? Cable routing for PROFIBUS or PROFINET connections to the Control Unit 1. Route the cable for the Control Unit from the bottom left in the cabinet. 2. Remove approximately 3 cm cable insulation from the cable at the height of the shield plate in the lower section of the cabinet. Attach the cable to the shield plate. 3. Attach the cable by snapping the retaining clamp into the shield plate in an EMC-compliant fashion. 4. Use cable ties to secure the cable at appropriate locations. 5. Feed the cable up through the cabinet and, at the height of the Control Unit, route it directly up and to the right towards the Control Unit. Route the cable corresponding to the standard cable prerouted in the cabinet. Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 89

90 Electrical connection 5.4 Cable routing 6. Use cable ties to secure the cable at appropriate locations. 7. Connect the cable to the Control Unit. Information regarding connecting the cable is provided in the "Control cabinets and supplementary system components" manual Cable routing for DRIVE-CLiQ connections and signal cables 1. Route the DRIVE-CLiQ/signal cable from the bottom left in the cabinet. 2. Use cable ties to secure the cable at appropriate locations. 3. Feed the cable up through the cabinet and, at the height of the Control Unit, route it directly up and to the right towards the Control Unit. Route the cable corresponding to the standard cable prerouted in the cabinet. 4. Use cable ties to secure the cable at appropriate locations. 5. Connect the DRIVE-CLiQ/signal cable to the Control Unit Cable routing to the customer terminal block -X55 1. Route the cable for the customer terminal block from the bottom left in the cabinet. 2. Remove approximately 3 cm cable insulation from the cable at the height of the shield plate in the lower section of the cabinet. Attach the cable to the shield plate. 3. Attach the cable by snapping the retaining clamp into the shield plate in an EMC-compliant fashion. 4. Use cable ties to secure the cable at appropriate locations. 5. Guide the cable further up into the cabinet and, when it reaches customer terminal block - X55, guide it to the left or right to -X55. Route the cable corresponding to the standard cable prerouted in the cabinet. 6. Use cable ties to secure the cable at appropriate locations. 7. Connect the cables to the customer terminal block X55. Optional interface -X55 You can find notes regarding the optional X-55 interface in the "SINAMICS S120 Cabinet Modules" Manual, in Chapter "Interface description" Cable routing for the Terminal Module TM54F The cable routing corresponds to the cable routing to the customer terminal block -X55. Connect the cables to the terminals to control the functions. 90 Operating Instructions, 04/2015, A5E A

91 Electrical connection 5.4 Cable routing Cable routing for signal cables to SMC10/20/30 Sensor Module 1. Route the cable for the customer terminal block from the bottom left in the cabinet. 2. Remove approximately 3 cm cable insulation from the cable at the height of the shield plate in the lower section of the cabinet. Attach the cable to the shield plate. 3. Attach the cable by snapping the retaining clamp into the shield plate in an EMC-compliant fashion. 4. Use cable ties to secure the cable at appropriate locations. 5. Guide the cable further up into the cabinet and, when it reaches the SMC10/20/30 Sensor Module ( B81/ B82/ B83), guide it to the right to the Sensor Module (encoder module). Route the cable corresponding to the standard cable prerouted in the cabinet. 6. Use cable ties to secure the cable at appropriate locations. 7. Connect the cables to the SMC10/20/30 Sensor Module ( B81/ B82/ B83) Cable routing to connect the motor 1. Route the cable into the cabinet from below. 2. Feed the cable up through the cabinet to the motor connections U2/-T1, -V2/-T2, -W2/-T3. 3. Connect the cable to the motor connections Cable routing for Active Line Modules Checklist Comply with the basic rules for cable routing (Page 86) when carrying out all cable routing and connection work. Route the following cables or carry out the following connection work: Table 5-6 Checklist for cable routing and connection work Cable routing PROFIBUS cable or PROFINET cable to the Control Unit DRIVE-CLiQ connections / signal cables to the Control Unit Signal cables to the customer terminal block X55 Completed? Cable routing for PROFIBUS or PROFINET connections to the Control Unit 1. Route the cable for the Control Unit from the bottom left in the cabinet. 2. Remove approximately 3 cm cable insulation from the cable at the height of the shield plate in the lower section of the cabinet. Attach the cable to the shield plate. 3. Attach the cable by snapping the retaining clamp into the shield plate in an EMC-compliant fashion. Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 91

92 Electrical connection 5.4 Cable routing 4. Use cable ties to secure the cable at appropriate locations. 5. Feed the cable up through the cabinet and, at the height of the Control Unit, route it directly up and to the right towards the Control Unit. Route the cable corresponding to the standard cable prerouted in the cabinet. 6. Use cable ties to secure the cable at appropriate locations. 7. Connect the cable to the Control Unit. Information regarding connecting the cable is provided in the "Control cabinets and supplementary system components" manual Cable routing for DRIVE-CLiQ connections and signal cables 1. Route the DRIVE-CLiQ/signal cable from the bottom left in the cabinet. 2. Use cable ties to secure the cable at appropriate locations. 3. Feed the cable up through the cabinet and, at the height of the Control Unit, route it directly up and to the right towards the Control Unit. Route the cable corresponding to the standard cable prerouted in the cabinet. 4. Use cable ties to secure the cable at appropriate locations. 5. Connect the DRIVE-CLiQ/signal cable to the Control Unit. 92 Operating Instructions, 04/2015, A5E A

93 Commissioning 6 For your personal safety and to prevent material damage when working on the converter, always carefully observe the safety instructions and the following five safety rules, according to EN "Working in a voltage-free state". Apply the five safety rules in the sequence stated before starting work on the converter. Five safety rules 1. Disconnect the system. Disconnect the auxiliary circuits, for example anti-condensation heating 2. Prevent reconnection. 3. Make sure that the equipment is at zero voltage 4. Ground and short-circuit 5. Cover or isolate nearby components that are still live. To energize the system, apply the measures in reverse order. 6.1 Commissioning the drive Detailed information on commissioning and operating the converter is provided in the Commissioning Manual designated for the commissioning engineer. You can find the commissioning instructions on the customer DVD. WARNING Incorrect commissioning Malfunctions can occur as a result of incorrect commissioning and parameterization. This can result in premature failures and subsequent damage to the drive and the drive system components. This can result in death, serious injury or material damage. Incorrectly performed commissioning can result in the warranty becoming null and void. This drive may only be commissioned by electrical technicians that 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". Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 93

94 Commissioning 6.2 Commissioning the cooling unit 6.2 Commissioning the cooling unit Operating Instructions For commissioning the cooling unit, observe its operating instructions. For cooling units supplied by Siemens, the operating instructions can be found in the terminal box. Deviating values When values in the associated operating instructions (e.g. pressure values) deviate from those of the cooling unit, the values of the associated operating instructions apply. Requirements placed on the cooling water of the inner cooling circuit You can find the requirements relating to the cooling water for the inner cooling circuit (converter cooling water) in the "SINAMICS S120 Power Units Chassis Liquid cooled" Manual in Chapter "Cooling circuit and cooling properties and condensation protection". Requirements placed on the cooling water of the outer cooling circuit Requirements placed on the cooling water of the outer cooling circuit (raw water) of the cooling unit supplied from Siemens is provided in Chapter "Technical data in Section "Specification of the untreated water (Page 143)" Anti-condensation measures Warm air can condense for liquid-cooled converters. This condensation depends on the air humidity and the temperature difference between the ambient air and the coolant. If converters and the cooling system are operated together, the temperature of the system ensures that no condensation occurs on electrical components. Factory setting of the coolant temperature The coolant temperature is set at the factory to 40 C with 60 seconds overrun. The cooling system continues to run when the converter is switched off. The overrun of the cooling system prevents condensation in the converter circuit and ensures a control range without derating. Changes to the coolant temperature To prevent condensation in the converter circuit, the following requirement must be satisfied: ambient temperature coolant temperature < 45 C 94 Operating Instructions, 04/2015, A5E A

95 Commissioning 6.2 Commissioning the cooling unit Observe the technical data in Chapter: "Converter ambient conditions". NOTICE Risk of short-circuit Condensation in the converter circuit caused by condensate can cause short-circuits in the converter and damage parts of the converter. Only change the factory setting of the coolant temperature when absolutely necessary. You must always maintain the permitted temperature ranges. NOTICE Risk of short-circuit If you operate the cooling system without converters, the temperature of the cooling liquid can fall below the ambient temperature. The cooling liquid can condense at electrical components and cause a short-circuit. Always operate the converters and the cooling system together. If the temperature of the coolant exceeds 45 C, this can result in derating of the converter Filling the cooling circuit Observe the five safety rules (Page 93). The commissioning requires a drum pump and a 1/2" hose. Because the coolant is delivered in 50 l drums, we recommend the use of a drum pump that produces a pressure of 3 bar. The drum pump is not included in the scope of delivery. A filling set (consisting of a drum pump, hoses and ball cocks) can be ordered from the manufacturer of the cooling unit. For additional information, refer to the operating instructions of the cooling unit. 1. Close all vent cocks and drain cocks. 2. Connect the drum pump with the hose to the filling connections of the cooling unit. 3. Open all ball cocks in the cooling unit. 4. Using the drum pump, pump the coolant into the cooling circuit until the pressure manometer shows approx. 2.5 bar. To observe the pressure manometer on the expansion vessel, depending on the version, swivel the pressure manometer from the switch box as appropriate for the cooling unit version. Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 95

96 Commissioning 6.2 Commissioning the cooling unit Prevent the ingress of dirt and foreign bodies into the cooling circuit Venting the cooling circuit Venting pumps First vent the pumps 1. Please always read the operating instructions of the cooling unit. The exact position of the venting screw is shown in the operating instructions of the cooling unit. Figure 6-1 Example: Venting screw of the pump Venting components Vent the components in the specified sequence: First vent the air-water heat exchanger Then, in a second step, vent the Basic Line Modules, Active Line Modules and Motor Modules The hose for venting the individual components can be found in the cabinet. Release the ventilation hose 1 from the cabinet frame. Hold the venting hose outside the cabinet in a bucket. 96 Operating Instructions, 04/2015, A5E A

97 Commissioning 6.2 Commissioning the cooling unit Figure 6-2 Venting hose Venting the air-to-water heat exchanger Vent all air-water heat exchangers. Proceed as follows: Figure 6-3 Example: Air-water heat exchanger 1. Hold the blue venting hose outside the cabinet in a bucket. 2. Open the venting valve at the heat exchanger so that air can escape. Continue venting until clear cooling liquid escapes in a continuous stream. 3. Close the venting valve. Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 97

98 Commissioning 6.2 Commissioning the cooling unit CAUTION Danger of injury caused by spray water The coolant is harmful to eyes and skin and can damage surfaces. If the air escapes intermittently, coolant spray can reach your skin or eyes. Therefore, wear appropriate protective clothing for all work on the converter. However, if your eyes or skin do come into contact with coolant, rinse the affected area thoroughly with tap water as soon as possible. If coolant has escaped, remove the liquid from the affected surfaces. Please refer to the EU safety data sheet of the coolant manufacturer. Venting Basic Line Modules, Active Line Modules, Motor Modules Stainless steel cooler You do not have to vent Active Line Modules and Motor Modules, size FXL/GXL with stainless steel cooler. Vent all Basic Line Modules, Active Line Modules and Motor Modules. Proceed as follows: 1. Hold the blue venting hose outside the cabinet in a bucket. 2. Open the venting valve 1 at the Basic Line Module, Active Line Module or Motor Module so that air can escape. Continue venting until clear cooling liquid escapes in a continuous stream. 3. Close the venting valve. 1 Venting valve Figure 6-4 Example: Venting Motor Modules 98 Operating Instructions, 04/2015, A5E A

99 Commissioning 6.2 Commissioning the cooling unit CAUTION Danger of injury caused by spray water The coolant is harmful to eyes and skin and can damage surfaces. If the air escapes intermittently, coolant spray can reach your skin or eyes. Therefore, wear appropriate protective clothing for all work on the converter. However, if your eyes or skin do come into contact with coolant, rinse the affected area thoroughly with tap water as soon as possible. If coolant has escaped, remove the liquid from the affected surfaces. Please refer to the EU safety data sheet of the coolant manufacturer. You can find additional notes in the "SINAMICS S120 Power Units Chassis Liquid Cooled/ Cooling Circuit and Coolant Properties and Condensation Protection/Commissioning" Manual. Checking the system standstill pressure The system standstill pressure falls significantly when the system is vented. Continue filling coolant into the system via the drum pump until the system standstill pressure is approx. 2.5 bar. Completing venting Vent the pumps and components and refill with short pauses several times. Allow the system to stabilize a short time after each venting so that the air can collect at the highest points. Because the coolant is viscous, the air bubbles only gather at the highest points slowly and with difficulty Commissioning Proceed as follows to commission the cooler: 1. Switch on the cooling unit power supply. 2. Commission the cooling unit in accordance with the manufacturer's operating instructions. Please always read the operating instructions of the cooling unit. 3. Switch the cooling unit from automatic operation to manual operation. Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 99

100 Commissioning 6.2 Commissioning the cooling unit 4. Switch a pump into manual operation. The water-air mixture is circulated. The air can accumulate at the highest points. If coolant is still not pumped when the pumps are first switched on, too much air is still present in the system. You vent the cooling unit as described in Chapter "Venting the cooling circuit (Page 96)". NOTICE Damage to the pumps The pumps can be damaged if they run dry. Make sure that the pumps do not run dry. 5. When the pumps operate, monitor the pressure manometer at the expansion vessel on the suction side of the pumps. The supply pressure increases once the pump feeds coolant. Although the return pressure decreases, it should not fall below 0.5 bar. To do this, monitor the pressure manometer at the expansion vessel. If the return pressure falls below 0.5 bar then there is insufficient coolant in the system. Add coolant as described in Chapter "Filling the cooling circuit (Page 95)". 6. Monitor the intake and return pump pressure at the operator panel of the cooling unit. The pump intake pressure should not exceed 5 bar. The integrated pressure relief valve responds at 6 bar. 7. After running the pump briefly, vent again as described in Chapter "Venting the cooling circuit (Page 96)" 8. The three-way valve in the idle state is at position "0". The cooling water is fed past the heat exchanger and air remains in the heat exchanger. When pumping, set the three-way valve to the "1" position. The heat exchanger fills with coolant. and displaces the air Control of the cooling unit To operate the cooling unit automatically, communication with a higher-level controller is necessary. The Siemens Logo control of the cooling unit communicates with the converter via DRIVE-CLiQ. To realize this, there must be a DRIVE-CLiQ connection between the CU320 Control Unit of the converter and terminal TM31 of the cooling unit. The converter communicates using the commands and feedback signals of the cooling unit described in the following. The following figure illustrates the communication between the controller of the cooling unit and the converter: 100 Operating Instructions, 04/2015, A5E A

101 Commissioning 6.2 Commissioning the cooling unit Logo control You can find additional information on operating the Logo control in the cooling unit operating instructions. TM31 You can find information about the TM31 terminal module in the "SINAMICS S120 Control Units and Additional System Components" Manual in Chapter, "Terminal Modules" Programming the interface Commands for controlling the cooling unit The following commands are potential-free signals from the converter to the cooling unit: Command Function name TM31 terminal Switching on and switching off the cooling unit If the cooling unit is in the ready state, then it is switched on with a rising signal edge. The cooling unit is switched off with a falling signal edge. The pump continues to run for x minutes. Stopping the cooling unit The cooling unit is immediately switched off with a falling signal edge. The pump does not continue to run. Acknowledge the alarms of the cooling unit Alarms and fault signals of the cooling unit are acknowledged with a rising signal edge. DI/DO8 DI/DO9 DI/DO10 -X541:2 -X541:3 -X541:4 Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 101

102 Commissioning 6.2 Commissioning the cooling unit Status signals of the cooling unit The following status signals are sent from the cooling unit to the converter: Status signal Function name TM31 terminal Cooling unit ready Low = cooling unit not ready High = cooling unit ready to switch on. You can start the converter. Cooling unit operates correctly. The cooling unit operates correctly after switch-on. A pump is running. The water pressure and the water level match the specifications. The coolant temperature lies within the correct range. Group alarm High = no alarm active Low = at least one alarm message is active Group fault High = no-fault active Low = at least one fault is active DI0 DI1 DI3 DI3 -X520:1 -X520:2 -X520:3 -X520:4 102 Operating Instructions, 04/2015, A5E A

103 Operation Safety instructions for operation Observe Chapter, "Safety instructions" when carrying out any work at the converter. DANGER Operation with the doors open High voltages are present in the drive and its components during operation and also after it has been switched off. When touched, these voltages can lead to death or severe injury. Ensure that no voltage is present when the doors are open. Never operate the drive with doors open. Faults WARNING Operating the drive when a fault has arisen can result in death, serious injury or substantial material damage. Observe the fault and alarm messages. Eliminate the source of the fault. Only put the drive back into operation once this is resolved. You can find further information on alarms and faults in the section "Fault indications and correction." If it is not possible to correct a fault, inform the manufacturer's service personnel immediately. For additional information, see Chapter "Service & support". WARNING Exceeding the permitted short-circuit currents Serious 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. Operation in an IT supply system Operation with a ground fault must be restricted to the absolutely shortest possible time. The plant operating company is responsible for the consequences, if the drive is still operated after a ground fault has been detected. Carry out a risk analysis. Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 103

104 Operation 7.2 Fault and system messages 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. Only trained personnel may operate the converter. 7.2 Fault and system messages Diagnostics You can find a description of the LEDs of the various modules in the following manuals on the CD provided: "Sinamics S120 Cabinet Modules" in Chapter, "Diagnostics", "Control Units and additional system components" Fault messages from the cooling unit In addition to the operating states, the following messages are displayed on the Logo control text display: Fault messages Alarm messages Limit value violations Messages You can find a detailed description of the possible messages in the cooling unit operating instructions. 104 Operating Instructions, 04/2015, A5E A

105 Servicing Safety instructions for maintenance Observe Chapter, "Safety instructions" when carrying out any work at the converter. WARNING Improper maintenance and repairs Improper repairs can result in death and serious physical injury. Only qualified maintenance and installation personnel may perform repairs. WARNING Danger as a result of defective seals When working on the device, seals at the doors, roof panels as well as front, rear and side panels can be damaged. Operating the device 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 specifications. WARNING High voltage when the anti-condensation heating is operational The anti-condensation heating system is used when the drive is switched off due to production downtime or maintenance. For this reason, the heating is supplied with voltage from a separate line supply. When the supply voltage for the anti-condensation heating is connected, dangerous voltages are present in the cabinet unit, even with EMERGENCY OFF or when the main switch is open. This voltage can cause serious injury. The five safety rules must be observed. WARNING Hot anti-condensation heating surface When the temperature control limit value is reached the anti-condensation heating is switched on. Once activated, the anti-condensation heating can generate a great deal of heat. Contact can result in serious injury, such as skin burns. Do not touch the anti-condensation heating. Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 105

106 Servicing 8.1 Safety instructions for maintenance CAUTION Risk of falling When 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. NOTICE Non-approved spare parts Using non-approved spare parts can affect the function of the equipment and damage it. Thirdparty spare parts and unapproved spare parts may not meet the requirements. Therefore, only use spare parts that have been approved by the manufacturer. NOTICE Foreign bodies in the drive If, after installation and maintenance work, foreign bodies are left in the drive, this can damage it when switching on. Before switching on, check as to whether there are any foreign bodies in the drive. Remove any foreign bodies. NOTICE Contamination 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. The actual intervals at which maintenance procedures are to be performed depend on the environmental and operating conditions. Define maintenance intervals for the drive which 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. 106 Operating Instructions, 04/2015, A5E A

107 Servicing 8.2 Preventive maintenance Siemens offers its customers support in the form of a service contract. For further details, contact your regional office or sales office. WARNING High voltage after shutdown High voltages are still present in the drive even after it has been shut down. Touching the drive can result in death or serious injury. Only work on the power unit if it has been sufficiently grounded. Before touching the drive, ensure that the following parts of the power unit are de-energized: Internal busbars Input and output terminals Auxiliary power supply Always observe the five safety rules (Page 13)when carrying out any work on the device. 8.2 Preventive maintenance Inspection 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 environmental conditions at the location of use. The following servicing and inspection instructions are used as the basis for regular inspection of the equipment Maintenance intervals The specified maintenance intervals are limit values that may need to be reduced depending on the operational conditions. The operating company must always ensure that an appropriate maintenance is performed. The maintenance intervals depend on the calendar time or the operating hours, whichever occurs first. Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 107

108 Servicing 8.2 Preventive maintenance Maintenance intervals of the components Table 8-1 Maintenance intervals Component Review Replacement Coolant Annually After ten years Cooling hoses Fan Gaskets Filter Pumps Regularly, at least every three months Regularly, at least every three months Regularly, at least every three months After six years After approximately 50,000 operating hours After six years See the notes in the cooling unit operating instructions See the notes in the cooling unit operating instructions Visual inspections Tools required You will need the following tools: Standard set of tools with screwdrivers, screw wrenches, socket wrenches, etc. Torque wrenches from 1.5 Nm up to 100 Nm 600 mm extension for socket wrenches Torques The following tightening torques apply when tightening current-conducting connections, e.g. DC-link connections, motor connections, busbars, lugs and other connections (for example ground connections, protective conductor connections, steel threaded connections/glands). Table 8-2 Tightening torques for screw connections Thread Ground connections, protective conductor connections, steel threaded connections Aluminum threaded connections, plastic, busbars, lugs M3 1.3 Nm 0.8 Nm M4 3 Nm 1.8 Nm M5 6 Nm 3 Nm M6 10 Nm 6 Nm M8 25 Nm 13 Nm M10 50 Nm 25 Nm M12 88 Nm 50 Nm M Nm 115 Nm 108 Operating Instructions, 04/2015, A5E A

109 Servicing 8.2 Preventive maintenance NOTICE Screw connections for protective covers The screw connections for the protective covers made of Makrolon may only be tightened with 2.5 Nm Servicing the cabinet Cable and screw terminals must be checked regularly to ensure that they are securely in position and, if necessary, retightened. Cabling must be checked for defects. Defective parts must be replaced immediately. Maintenance intervals The actual intervals depend on the installation (the environment in which the cabinet is installed) and operating conditions. Siemens offers its customers support in the form of a service contract. For further details, contact your regional office or sales office. NOTICE Contamination 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. The actual intervals at which maintenance procedures are to be performed depend on the environmental and operating conditions. Define maintenance intervals for the drive which 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 Checking the isolating clearances Slight, dry, non-conducting contamination is permitted. Remove contamination caused by dust in conjunction with high humidity. Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 109

110 Servicing 8.3 Waiting Checking the plug connections. Regularly check the plug connections to ensure they are seated correctly and the contacts are not corroded. The fiber-optic cables for the gating boards must be properly inserted in the connectors 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 108). Check the cabling for defects. Replace any defective parts immediately 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. See also Cleaning (Page 118) 8.3 Waiting Replacing filter mats When your converter is equipped with filter mats, check the filter mats for accumulated dirt at regular intervals. You must replace the filter mats if the amount of accumulated dirt means that an insufficient amount of air is entering the converter. Replacing the filter mats If you do not replace dirty filter mats, this can cause a premature thermal shutdown of the drive. Make sure that no dirt can enter the cabinet. When disposing the filter mats comply with the applicable legal stipulations. The ordering data for the filter mats is provided in the spare parts list. 110 Operating Instructions, 04/2015, A5E A

111 Servicing 8.3 Waiting Replacing filter mats Figure 8-1 Replacing filter mats 1. Comply with the five safety rules. 2. Bring the cabinet into a no-voltage condition, including the external power supplies. The cabinet must be disconnected from the power supply to prevent the fans from drawing in polluted external air. If the fans are supplied externally, take into account possible fan run-on. Also disconnect this power supply. 3. Allow unimpeded access to the mesh area in the doors. 4. Place the screwdriver in the recesses 1 provided. Applying slight pressure, push the screwdriver downwards. Tilt the mesh cover towards the front and remove it. 5. Remove the filter mat 2 and clean the ventilation mesh under the filter. 6. Insert a new filter mat. Correct seating of filter mats For filter mats with degree of protection IP54, insert the mat so that the arrow points towards the cabinet. Locate the filter mat at the upper guide edge Reattach the mesh cover. Snap the cover back into the recesses by applying slight pressure. 8. Repeat the process for all of the filter mats to be replaced Replacing the back-up battery of the AOP30 operator panel Table 8-3 Technical specifications of the backup battery Type CR2032 3V lithium battery Manufacturer Maxell, Sony, Panasonic Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 111

112 Servicing 8.3 Waiting Nominal capacity Maximum permissible charging current Self-discharge at 20 C Service life in the backup mode Service life in operation 220 mah 10 ma, limited to < 2 ma in the operator panel 1%/year > 1 year at 70 C; >1.5 years at 20 C > 2 years Replacing the backup battery 1. 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. 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 8-2 Replacing the backup battery Dispose of the battery in accordance with the applicable country-specific laws and regulations. 112 Operating Instructions, 04/2015, A5E A

113 Servicing 8.3 Waiting Set date and time 1. Using the "MENU" key, select the main menu of the AOP 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 Loading operator panel firmware, parameter and signal descriptions As of software version V2.4, the following data is stored on the CompactFlash card of the drive: The AOP firmware The parameter and signal descriptions All operator panel languages The new software version is detected during the initial activation of the AOP on a drive. The following data is displayed: Firmware being loaded Yes: Vxx.xx.xx (new software version) No: Vxx.xx.xx (currently loaded software version) Press the "F5" key ("Yes") on the AOP to confirm the selection of the new software version. The firmware will be loaded. This procedure takes approx. five minutes. While loading, do not switch off the power supply for the drive and AOP. If the loading process for the new firmware is not completed successfully because of a a power outage or the connection process, the currently loaded firmware is retained. The prompt appears at the next switch on. If a power outage or aborted connection occurs during the last 20 seconds of the loading process, the AOP firmware is destroyed. In this case, reload the firmware from the product CD via the PC with "LOAD_AOP30". Reloading the firmware 1. Establish the RS232 connection from the PC to the AOP Switch on the 24 V power supply. 3. On the PC, launch the LOAD_AOP30 program. 4. Choose the PC interface (COM1, COM2). Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 113

114 Servicing 8.3 Waiting 5. Choose the firmware (AOP30.H86) and open the file. 6. Follow the instructions in the program status window. Switch on the AOP30 using the red button (O). Loading begins Maintaining the cooling circuit Check the complete cooling circuit for leaks at regular intervals, at least every 3 months. When maintaining the cooling circuit, observe the operating instructions provided by the component manufacturer. 114 Operating Instructions, 04/2015, A5E A

115 Servicing 8.3 Waiting Servicing the filter for a cooling unit supplied from Siemens Check the filter once yearly and clean if necessary. Proceed as follows: 1. Open bypass valve 1 of the filter. Close shutoff valve 2 before and after the filter. Figure 8-3 Shutoff and bypass valves 2. Unscrew the filter cartridge. Check the filter for accumulated pollution and dirt. If the filter is dirty, clean it under flowing water. Figure 8-4 Removing the filter Coolant CAUTION Coolant can escape when the filter is opened. The coolant is harmful to eyes and skin and can damage surfaces. Therefore, wear appropriate protective clothing for all work on the converter. However, if your eyes or skin do come into contact with coolant, rinse the affected area thoroughly with tap water as soon as possible. If coolant leaks, eliminate the source of the problem and remove the liquid from the surfaces affected. 3. Screw the filter back in and close bypass valve 1. Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 115

116 Servicing 8.3 Waiting Maintaining and replacing coolant hoses Inspect the coolant hoses every year for cracks and leaks. Replace any coolant hoses that have cracks or leaks. If the hose couplings leak, then replace the EPDM seal/gasket. Coolant CAUTION Coolant can escape when the coolant hoses are disconnected. The coolant is harmful to eyes and skin and can damage surfaces. Therefore, wear appropriate protective clothing for all work on the converter. However, if your eyes or skin do come into contact with coolant, rinse the affected area thoroughly with tap water as soon as possible. If coolant leaks, eliminate the source of the problem and remove the liquid from the surfaces affected. Replacing coolant hoses Before you start to replace the coolant hoses carefully ensure that there is no coolant in the hoses. Removing coolant hoses Proceed as follows: 1 2 Union nuts of the hose connections Quick-release locks on the collecting pipes 116 Operating Instructions, 04/2015, A5E A

117 Servicing 8.3 Waiting 1. Cut/release the cable ties that hold the coolant hoses. 2. Release the union nuts of the hose connections 1 at the converter. 3. Tighten the quick-release locks on the collecting pipes Release the hose clips at the ends of the coolant hoses. 5. Remove the hose couplings by turning and applying a little force. Installing coolant hoses Proceed as follows: 1. Shorten the new hoses so they have the same length as the removed hoses. 2. Fit the hose clips. 3. Apply some silicon-free lubricant to the hose bushings. At both ends, insert the hose couplings into the hose. Insert the hose couplings up to the end stop. 4. Maintain a 10 mm clearance between the hose clamps and the end of the hose. Tighten the hose clamps with a torque of 4 Nm. 5. Insert the hoses in the converter: Use new flat seals for the union nuts. Maintain a minimum separation of 25 mm between the busbars and the coolant hoses. Do not bend the hoses. To prevent bends in the hoses, choose the same routing path as delivered. Fix the hoses with cable ties. NOTICE Damage to the coolant hoses caused by sharp objects Damage can occur to the coolant hoses if you use sharp objects for the installation. The coolant hoses can leak. Leaking coolant can damage the converter. Avoid applying force with pointed objects (e.g. screwdrivers) to the coolant hoses. Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 117

118 Servicing 8.4 Cleaning Maintaining the pumps Check the pumps every three months for smooth running, leaks and normal housing temperatures. If the pumps leak, then please contact Technical Support (Page 139) Maintaining the fans of the additional cooler Perform a visual inspection every three months. During the visual inspection of the fans, check for smooth running and normal housing temperatures. The average service life of the fans is approximately 50,000 hours. However, the actual service life depends on additional influencing quantities, for example, the ambient temperature and cabinet degree of protection. As a consequence, the service life can deviate from this value on a case-for-case basis. Replace the fan in a timely manner in order to maintain the availability of the drive. See also Replacing the fan of the additional cooler (degree of protection IP54) (Page 129) 8.4 Cleaning Removing dust deposits Remove dust deposits at least once per year. You can use an ESD brush or an ESD vacuum cleaner. The ventilation openings in the cabinet must never be obstructed. NOTICE Cleaning fiber-optic cables and electronic components with a damp rag Fiber-optic cables, fiber-optic cable bundles and electronic components can be damaged if cleaned using a damp rag. If the components are very dusty, remove the dust using a dry, lint-free cloth. In so doing, do not bend the fiber-optic cables Cleaning frame components 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 severe pollution, use a cleaning cloth soaked in ethyl alcohol, but not to the extent that the alcohol drips. 118 Operating Instructions, 04/2015, A5E A

119 Servicing 8.5 Repairs Cleaning aluminum parts The surface of untreated aluminum is always covered by a thin but dense oxide skin. The affinity of aluminum to oxygen is sufficiently strong that if the oxide skin is scratched, the metal reacts immediately with oxygen in the air. This forms a new 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 particularly greasy deposits with ethyl alcohol. If there are other heavily polluted areas, use ESD-compliant fiber or plastic brushes to clean them. NOTICE Unsuitable cleaning chemicals for aluminum Any strongly alkaline chemicals such as caustic potash or soda as well as acids corrode the aluminum and roughen the surface. The agents often recommended for cleaning glass also exhibit this effect and must therefore not be used on aluminum. Only use cleaning agents that are suitable for aluminum. NOTICE Unsuitable cleaning utensils for aluminum The use of unsuitable cleaning cloths and brushes may transfer metallic, corrosion-inducing impurities onto the aluminum. This can result in corrosion damage. 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. 8.5 Repairs WARNING Insufficient 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. Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 119

120 Servicing 8.5 Repairs NOTICE Drive failure 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 damage to the drive. We recommend using an uninterruptible power supply (UPS). If you are unsure of the measures necessary after the drive fails, or if a fault cannot be rectified, contact the Service Center. Fastening the cable ducts 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 86)" Replacing power components Installation device for chassis units You require mounting equipment to install and remove the built-in units Basic Line Modules, Active Line Modules and Motor Modules. You can order the mounting equipment through the sales organization. 120 Operating Instructions, 04/2015, A5E A

121 Servicing 8.5 Repairs Figure 8-5 Mounting aid The mounting equipment is a mounting aid that is located in front of the built-in unit. The mounting equipment is attached to the cabinet frame and to the rails of the built-in unit. With its telescopic feet, the mounting equipment can be adapted to the installation height of the built-in units. After releasing the mechanical and electrical connections at the built-unit, the built-in unit can be withdrawn from the cabinet using the cable winch, and placed down in front of the cabinet. The built-in unit is guided by the rails of the slide-in devices. the manufacturer's instructions and the safety instructions for the installation and the handling of the mounting equipment. Comply with the "five safety rules". Disconnect the cabinet from the power supply. Do not forget the external power supplies. Remove the protective cover. Allow free access to the components to be replaced. Assemble the mounting equipment for the power unit components. Have the mounting equipment ready for use. Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 121

122 Servicing 8.5 Repairs Removing Basic Line Modules Figure 8-6 Diagram showing the principle when replacing Basic Line Modules (frame size GBL) 122 Operating Instructions, 04/2015, A5E A

123 Servicing 8.5 Repairs Removing The steps for removal are numbered in accordance with the figures in the diagram. 1. Release and remove the holding plates at the top and bottom. 2. Loosen and remove the upper front cover. 3. Release and remove the DC busbar at the fuses at the device. 4. Release and remove the jumpers of the AC busbars. 5. Withdraw the two DRIVE-CLiQ cables and the plug connectors for the signal cables. 6. Remove the four rear fixing screws at the top and bottom. 7. Release the quick-release couplings of the cooling circuit at the collecting pipes. To prevent interchanging the supply and return when reinstalling, mark the associated connections before separating them. 8. Attach the two rails of the mounting equipment using four screws. 9. Withdraw the module from the cabinet using the mounting equipment (Page 120). CAUTION Damaging signal cables and cables Signal cables and cables can be damaged if the mounting equipment is incorrectly operated when withdrawing the module. When withdrawing the module, carefully comply with the safety instructions of the mounting equipment. The notes are provided in the operating instructions provided with the mounting equipment. Placing down the module If you wish to place down the module after it has been withdrawn, before using the crane you must attach the crane eyebolts and protective bar. s on this are provided in the "Power Units Chassis, Liquid Cool" Manual, in Chapter "Installation" of the corresponding module. Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 123

124 Servicing 8.5 Repairs Removing Active Line Modules Figure 8-7 Diagram showing the principle when replacing Active Line Modules (frame size JXL) 124 Operating Instructions, 04/2015, A5E A

125 Servicing 8.5 Repairs Removing The steps for removal are numbered in accordance with the figures in the diagram. 1. Release and remove the holding plates at the top and bottom. 2. Loosen and remove the upper front cover. 3. Release and remove the DC busbar at the fuses at the device. 4. Release and remove the jumpers of the AC busbars. 5. Withdraw the two DRIVE-CLiQ cables and the plug connectors for the signal cables. 6. Remove the four rear fixing screws at the top and bottom. 7. Release the quick-release couplings of the cooling circuit at the collecting pipes. To prevent interchanging the supply and return when reinstalling, mark the associated connections before separating them. 8. Attach the two rails of the mounting equipment using four screws. 9. Withdraw the module from the cabinet using the mounting equipment (Page 120). CAUTION Damaging signal cables and cables Signal cables and cables can be damaged if the mounting equipment is incorrectly operated when withdrawing the module. When withdrawing the module, carefully comply with the safety instructions of the mounting equipment. The notes are provided in the operating instructions provided with the mounting equipment. Placing down the module If you wish to place down the module after it has been withdrawn, before using the crane you must attach the crane eyebolts and protective bar. s on this are provided in the "Power Units Chassis, Liquid Cool" Manual, in Chapter "Installation" of the corresponding module. Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 125

126 Servicing 8.5 Repairs Removing Motor Modules Figure 8-8 Replacing the Motor Module 126 Operating Instructions, 04/2015, A5E A

127 Servicing 8.5 Repairs Removing The steps for removal are numbered in accordance with the figures in the diagram. 1. Release and remove the holding plates at the top and bottom. 2. Loosen and remove the upper front cover. 3. Release and remove the DC busbar at the fuses at the device. 4. Release and remove the jumpers of the AC busbars. 5. Withdraw the two DRIVE-CLiQ cables and the plug connectors for the signal cables. 6. Remove the four rear fixing screws at the top and bottom. 7. Release the quick-release couplings of the cooling circuit at the collecting pipes. To prevent interchanging the supply and return when reinstalling, mark the associated connections before separating them. 8. Attach the two rails of the mounting equipment using four screws. 9. Withdraw the module from the cabinet using the mounting equipment (Page 120). CAUTION Damaging signal cables and cables Signal cables and cables can be damaged if the mounting equipment is incorrectly operated when withdrawing the module. When withdrawing the module, carefully comply with the safety instructions of the mounting equipment. The notes are provided in the operating instructions provided with the mounting equipment. Placing down the module If you wish to place down the module after it has been withdrawn, before using the crane you must attach the crane eyebolts and protective bar. s on this are provided in the "Power Units Chassis, Liquid Cool" Manual, in Chapter "Installation" of the corresponding module. Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 127

128 Servicing 8.5 Repairs Installing power unit components Installing power unit components Install the intact power unit components in the reverse order of the steps described for removal. When tightening the screws, make sure that you use the appropriate torque (Page 108) permissible for each screw type. Carefully insert the plug connections. Check that the connection is secure. Only tighten the screw connections for the protective covers by hand. Remove the crane eyebolts and the mounting equipment. Quick-release couplings If you replace power unit components, you must remove the quick-release couplings of the cooling circuit from the defective module and attached them to the new module Replacing the fan of the Active Interface Module Replacing the fan of the Active Interface Module You can find a description of how to replace the fan in the "SINAMICS S120 Power Units Chassis Liquid Cooled" Manual, Chapter "Replacing the fan, Active Interface Module". 128 Operating Instructions, 04/2015, A5E A

129 Servicing 8.5 Repairs Replacing the fan of the additional cooler (degree of protection IP54) Removing the fan of the 3 kw additional cooler Figure 8-9 Replacing the fan motor Removal The steps for removal are numbered in accordance with the figures in the diagram. 1. Release and remove the holding plate. 2. Release and remove the connecting cable at the terminal block. 3. Release and remove the mounting plate of the fan. 4. Withdraw the fan from the guides. When doing this, do not damage any of the signal cables. Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 129

130 Servicing 8.5 Repairs Removing the fan of the 0.8 kw additional cooler Figure 8-10 Replacing the fan motor Removal steps The steps for removal are numbered in accordance with the figures in the diagram. 1. Release and remove the connecting cable at the terminal block. 2. Remove the four screws for the fan cover. Remove the fan cover together with the fan motor. When doing this, do not damage any of the signal cables Installing the fan of the additional cooler Installing the fan Install the intact fan in the reverse order of the steps described for removal. When tightening the screws, make sure that you use the appropriate torque (Page 108) permissible for each screw type. Only tighten the screw connections for the protective covers by hand Replacing the fuses Comply with the "five safety rules". Disconnect the cabinet from the power supply. Do not forget the external power supplies. 130 Operating Instructions, 04/2015, A5E A

131 Servicing 8.5 Repairs Remove the protective cover. Allow free access to the fuses Replacing DC fuses Replacing the fuses Figure 8-11 Replacing the DC fuses To replace the fuses, proceed as follows: 1. Loosen the screws 1 of the fuse. Do not remove the screws. 2. Swivel the fuse upwards and towards the front. Remove the fuse. To replace the fuse, you must first remove the front fuse. 3. Install the intact fuse in the reverse order. Observe the permissible torque (Page 108) when tightening the fuse screws. NOTICE Device failure after a DC fuse ruptures The neighboring DC fuses may also become damaged if a DC fuse ruptures. This can result in device failure. After a DC fuse ruptures, always replace all DC fuses at the same time. Always use fuses of the same type. Siemens Drives & PLCs Operating Instructions, 04/2015, A5E A 131