Siemens SINAMICS S120 Operating Instructions Manual

Brand: Siemens

Model: SINAMICS S120

Type: Operating Instructions Manual

Operating instructions

SINAMICS S120

Applications for Cabinet Modules, liquid-cooled

04/2015

Edition

Answers for industry.

Siemens Drives & PLCs

SINAMICS

S120

Applications for Cabinet Modules,

liquid cooled

Operating Instructions

04/2015

A5E35974555A

Introduction

Safety notes

Description

Preparations for use

Installation

Electrical connection

Commissioning

Operation

Servicing

Spare parts

Disposal

Service & Support

Technical data

Checklists and forms

Siemens Drives & PLCs

Legal information

Warning notice system

This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent

damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert

symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are

graded according to the degree of danger.

DANGER

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

WARNING

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

CAUTION

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

NOTICE

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

If more than one degree of danger is present, the warning notice representing the highest degree of danger will be

used.

A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property

damage.

Qualified Personnel

The product/system described in this documentation may be operated only by personnel qualified for the specific

task in accordance with the relevant documentation, in particular its warning notices and safety instructions. Qualified

personnel are those who, based on their training and experience, are capable of identifying risks and avoiding

potential hazards when working with these products/systems.

Proper use of Siemens products

Note the following:

WARNING

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

documentation.

If products and components from other manufacturers are used, these must be recommended or

approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and

maintenance are required to ensure that the products operate safely and without any problems. The permissible

ambient conditions must be complied with. The information in the relevant documentation must be observed.

Trademarks

All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication

may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.

Disclaimer of Liability

We have reviewed the contents of this publication to ensure consistency with the hardware and software described.

Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in

this publication is reviewed regularly and any necessary corrections are included in subsequent editions.

Siemens AG

Division Process Industries and Drives

Postfach 48 48

90026 NÜRNBERG

GERMANY

Order number: Review_A5E35598443A

Ⓟ 04/2015 Subject to change

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.

Note

A Note is an important item of information about the product, handling of the product or the

relevant section of the document. Notes provide you with help or further suggestions/ideas.

Applications for Cabinet Modules, liquid cooled

Operating Instructions, 04/2015, A5E35974555A 5

Siemens Drives & PLCs

Introduction

Applications for Cabinet Modules, liquid cooled

6 Operating Instructions, 04/2015, A5E35974555A

Table of contents

Introduction...................................................................................................................................................5

1 Safety notes................................................................................................................................................13

1.1 Qualified personnel................................................................................................................13

1.2 The five safety rules...............................................................................................................13

1.3 Safe handling.........................................................................................................................14

1.4 Electromagnetic fields in electrical power engineering installations ......................................16

1.5 Components that can be destroyed by electrostatic discharge (ESD)...................................17

1.6 Information for persons responsible for plants and systems..................................................18

1.6.1 Proper usage..........................................................................................................................18

1.6.2 Grounding concept.................................................................................................................20

1.6.3 Installation site safety.............................................................................................................20

1.6.4 Instructions for inverters with no grounding switch................................................................21

1.6.5 Measures for operator protection in electromagnetic fields...................................................21

1.7 Residual risks.........................................................................................................................21

2 Description..................................................................................................................................................25

2.1 Overview................................................................................................................................25

2.2 Field of application.................................................................................................................25

2.3 Benefits..................................................................................................................................26

2.4 System structure....................................................................................................................27

2.5 Description of the components...............................................................................................27

2.5.1 Line Connection Module........................................................................................................27

2.5.2 Basic Line Module..................................................................................................................27

2.5.3 Active Line Module.................................................................................................................28

2.5.4 Motor Modules.......................................................................................................................28

2.5.5 Central Braking Module..........................................................................................................28

2.5.6 Auxiliary Power Supply Modules............................................................................................28

2.5.7 Re-cooling unit.......................................................................................................................29

2.6 Description of the optional components.................................................................................29

2.6.1 AOP30 Advanced Operator Panel.........................................................................................29

2.6.2 Output-side circuit-breaker.....................................................................................................29

2.6.3 Operation in an IT supply system...........................................................................................29

2.6.4 CBC10 Communication Board...............................................................................................30

2.6.5 CBE20 Communication Board...............................................................................................30

2.6.6 Control Unit CU320-2 DP; Control Unit 320-2 PN..................................................................30

2.6.7 dv/dt filter compact plus Voltage Peak Limiter.......................................................................31

2.6.8 du/dt filter plus Voltage Peak Limiter......................................................................................31

2.6.9 EMC shield bus......................................................................................................................31

2.6.10 Grounding switch downstream of main breaker.....................................................................32

2.6.11 Grounding switch upstream of main breaker.........................................................................32

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2.6.12 Holder for ARC detector.........................................................................................................32

2.6.13 Main contactor for Line Connection Modules < 800 A...........................................................32

2.6.14 Auxiliary power generation in the Line Connection Module...................................................33

2.6.15 Insulation monitoring..............................................................................................................33

2.6.16 Cable-marshaling compartment 200 mm high.......................................................................33

2.6.17 Circuit breaker in withdrawable unit design............................................................................34

2.6.18 Fan power supply...................................................................................................................34

2.6.19 Measuring device for line supply variables............................................................................34

2.6.20 Measuring device for line supply variables with PROFIBUS connection...............................35

2.6.21 Motor reactor..........................................................................................................................35

2.6.22 Line connection from above...................................................................................................35

2.6.23 TM150 Temperature Sensor Module.....................................................................................36

2.6.24 Terminal Module TM54F........................................................................................................36

2.6.25 Safe Brake Adapter SBA 230 V AC.......................................................................................36

2.6.26 Closed cabinet door (air inlet from below through floor opening)...........................................37

2.6.27 IP21 degree of protection.......................................................................................................38

2.6.28 Degree of protection IP23......................................................................................................38

2.6.29 IP43 degree of protection.......................................................................................................38

2.6.30 IP54 degree of protection.......................................................................................................39

2.6.31 Contactor monitoring..............................................................................................................39

2.6.32 SMC10 Sensor Module..........................................................................................................39

2.6.33 SMC20 Sensor Module..........................................................................................................40

2.6.34 SMC30 Sensor Module..........................................................................................................40

2.6.35 SMC30 Sensor Module, additional.........................................................................................40

2.6.36 Base 100 mm high.................................................................................................................41

2.6.37 Anti-condensation heating......................................................................................................41

2.6.38 Current transformer upstream of the main switch..................................................................41

2.6.39 Voltage Sensing Module VSM10...........................................................................................41

3 Preparations for use...................................................................................................................................43

3.1 Requirements regarding the installation site..........................................................................43

3.2 Inspections when the equipment is received.........................................................................45

3.2.1 Checking the delivery.............................................................................................................45

3.2.2 Checking shock and tilt indicators..........................................................................................46

3.2.3 Checking the load handling attachments...............................................................................49

3.3 Transport................................................................................................................................49

3.3.1 Transport markings................................................................................................................49

3.3.2 Transport requirements..........................................................................................................50

3.3.3 Take the center of gravity into account..................................................................................50

3.3.4 Transport with a fork-lift truck.................................................................................................51

3.3.5 Transporting using a crane....................................................................................................51

3.3.6 Transporting transportation units packed in boxes................................................................54

3.3.7 Disassembling the crane transport assembly........................................................................55

3.4 Unpacking the cabinets..........................................................................................................56

3.4.1 Removing the packaging........................................................................................................56

3.4.2 Removing load securing devices...........................................................................................56

3.4.3 Lifting the cabinet units off the transport pallet and installing them........................................57

3.4.4 Checking the shock and tilt indicators inside the cabinet.......................................................57

3.5 Storage ..................................................................................................................................58

3.5.1 Emptying the drive.................................................................................................................58

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8 Operating Instructions, 04/2015, A5E35974555A

3.5.2 Storing a device.....................................................................................................................59

3.5.3 Forming DC link capacitors....................................................................................................60

3.5.4 Storing re-cooling units..........................................................................................................61

3.5.4.1 Draining the cooling circuit.....................................................................................................62

4 Installation..................................................................................................................................................65

4.1 Safety instructions for assembly............................................................................................65

4.2 Tools required........................................................................................................................66

4.3 Torques..................................................................................................................................66

4.4 Connecting to the foundation.................................................................................................67

4.5 Connections of transport units...............................................................................................67

4.5.1 Connecting the collecting pipes of the cooling circuit.............................................................67

4.5.2 Connecting the converter system with the cooling unit..........................................................68

4.5.3 Connecting cabinets...............................................................................................................69

4.5.4 Connecting the DC and PE busbars......................................................................................71

4.5.4.1 Connecting the DC busbar.....................................................................................................71

4.5.4.2 Connecting the PE busbar.....................................................................................................73

4.5.4.3 Connecting-up according to the plant-side grounding concept..............................................74

4.5.4.4 Connecting cables brought out to the PE busbar...................................................................74

5 Electrical connection...................................................................................................................................75

5.1 Safety instructions for electrical connections.........................................................................75

5.2 Electromagnetic compatibility.................................................................................................77

5.3 Connection.............................................................................................................................80

5.3.1 Preparations for connecting the power cables.......................................................................80

5.3.2 Connecting the motor cable...................................................................................................81

5.3.3 Line/power connections.........................................................................................................83

5.3.4 Connecting the ground...........................................................................................................84

5.3.4.1 Connection according to the system-side grounding concept................................................84

5.3.4.2 Connecting external cables to the PE busbar........................................................................84

5.3.5 Operation on an isolated line supply (IT supply system)........................................................85

5.3.6 Signal connections.................................................................................................................85

5.3.7 Other connections..................................................................................................................85

5.3.8 Fastening the cable ducts with cable ties...............................................................................86

5.4 Cable routing..........................................................................................................................86

5.4.1 Basic rules for cable routing...................................................................................................86

5.4.2 Safety and EMC.....................................................................................................................87

5.4.3 Cable routing for Basic Line Modules....................................................................................87

5.4.3.1 Cable routing for PROFIBUS or PROFINET connections to the Control Unit........................88

5.4.3.2 Cable routing for DRIVE-CLiQ connections and signal cables..............................................88

5.4.3.3 Cable routing to the customer terminal block -X55................................................................88

5.4.4 Cable routing for Motor Modules............................................................................................89

5.4.4.1 Cable routing for PROFIBUS or PROFINET connections to the Control Unit........................89

5.4.4.2 Cable routing for DRIVE-CLiQ connections and signal cables..............................................90

5.4.4.3 Cable routing to the customer terminal block -X55................................................................90

5.4.4.4 Cable routing for the Terminal Module TM54F......................................................................90

5.4.4.5 Cable routing for signal cables to SMC10/20/30 Sensor Module...........................................91

5.4.4.6 Cable routing to connect the motor........................................................................................91

5.4.5 Cable routing for Active Line Modules...................................................................................91

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Applications for Cabinet Modules, liquid cooled

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Siemens Drives & PLCs

5.4.5.1 Checklist.................................................................................................................................91

5.4.5.2 Cable routing for PROFIBUS or PROFINET connections to the Control Unit........................91

5.4.5.3 Cable routing for DRIVE-CLiQ connections and signal cables..............................................92

6 Commissioning...........................................................................................................................................93

6.1 Commissioning the drive........................................................................................................93

6.2 Commissioning the cooling unit.............................................................................................94

6.2.1 Anti-condensation measures..................................................................................................94

6.2.2 Filling the cooling circuit.........................................................................................................95

6.2.2.1 Venting the cooling circuit......................................................................................................96

6.2.3 Commissioning.......................................................................................................................99

6.2.4 Control of the cooling unit....................................................................................................100

6.2.4.1 Programming the interface...................................................................................................101

7 Operation..................................................................................................................................................103

7.1 Safety instructions for operation...........................................................................................103

7.2 Fault and system messages................................................................................................104

7.2.1 Diagnostics...........................................................................................................................104

7.2.2 Fault messages from the cooling unit..................................................................................104

8 Servicing...................................................................................................................................................105

8.1 Safety instructions for maintenance.....................................................................................105

8.2 Preventive maintenance.......................................................................................................107

8.2.1 Inspection.............................................................................................................................107

8.2.2 Maintenance intervals..........................................................................................................107

8.2.3 Visual inspections................................................................................................................108

8.2.3.1 Tools required......................................................................................................................108

8.2.3.2 Torques................................................................................................................................108

8.2.3.3 Servicing the cabinet............................................................................................................109

8.2.3.4 Checking the isolating clearances........................................................................................109

8.2.3.5 Checking the plug connections............................................................................................110

8.2.3.6 Checking the cable and screw terminals..............................................................................110

8.2.3.7 Checking the filter mats........................................................................................................110

8.3 Waiting.................................................................................................................................110

8.3.1 Replacing filter mats.............................................................................................................110

8.3.2 Replacing the back-up battery of the AOP30 operator panel ..............................................111

8.3.3 Loading operator panel firmware, parameter and signal descriptions.................................113

8.3.4 Maintaining the cooling circuit..............................................................................................114

8.3.4.1 Servicing the filter for a cooling unit supplied from Siemens................................................115

8.3.4.2 Maintaining and replacing coolant hoses.............................................................................116

8.3.4.3 Maintaining the pumps.........................................................................................................118

8.3.4.4 Maintaining the fans of the additional cooler........................................................................118

8.4 Cleaning...............................................................................................................................118

8.4.1 Removing dust deposits.......................................................................................................118

8.4.2 Cleaning frame components................................................................................................118

8.4.3 Cleaning aluminum parts.....................................................................................................119

8.5 Repairs.................................................................................................................................119

8.5.1 Replacing power components..............................................................................................120

8.5.1.1 Installation device for chassis units......................................................................................120

Table of contents

Applications for Cabinet Modules, liquid cooled

10 Operating Instructions, 04/2015, A5E35974555A

8.5.1.2 Removing Basic Line Modules.............................................................................................122

8.5.1.3 Removing Active Line Modules............................................................................................124

8.5.1.4 Removing Motor Modules....................................................................................................126

8.5.1.5 Installing power unit components.........................................................................................128

8.5.2 Replacing the fan of the Active Interface Module.................................................................128

8.5.3 Replacing the fan of the additional cooler (degree of protection IP54)................................129

8.5.3.1 Removing the fan of the 3 kW additional cooler...................................................................129

8.5.3.2 Removing the fan of the 0.8 kW additional cooler................................................................130

8.5.3.3 Installing the fan of the additional cooler..............................................................................130

8.5.4 Replacing the fuses..............................................................................................................130

8.5.4.1 Replacing DC fuses.............................................................................................................131

8.5.4.2 Replacing AC fuses..............................................................................................................132

9 Spare parts...............................................................................................................................................135

10 Disposal....................................................................................................................................................137

10.1 Disposing of packaging material..........................................................................................137

10.2 Removing device components and old devices...................................................................137

A Service & Support.....................................................................................................................................139

A.1 Siemens Industry Online Support........................................................................................139

B Technical data..........................................................................................................................................141

B.1 General technical system data.............................................................................................141

B.2 Specification of the untreated water.....................................................................................143

C Checklists and forms................................................................................................................................145

C.1 Mechanical installation: Checklist........................................................................................145

C.2 Electrical installation: Checklist............................................................................................146

Index.........................................................................................................................................................151

Table of contents

Applications for Cabinet Modules, liquid cooled

Operating Instructions, 04/2015, A5E35974555A 11

Siemens Drives & PLCs

Table of contents

Applications for Cabinet Modules, liquid cooled

12 Operating Instructions, 04/2015, A5E35974555A

Safety notes

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 50110‑1

"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.

Applications for Cabinet Modules, liquid cooled

Operating Instructions, 04/2015, A5E35974555A 13

Siemens Drives & PLCs

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.

Safety notes

1.3 Safe handling

Applications for Cabinet Modules, liquid cooled

14 Operating Instructions, 04/2015, A5E35974555A

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.

Safety notes

1.3 Safe handling

Applications for Cabinet Modules, liquid cooled

Operating Instructions, 04/2015, A5E35974555A 15

Siemens Drives & PLCs

CAUTION

Places that are difficult to access

If you do not use appropriate protective equipment when working in places that are difficult

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.

CAUTION

Coolant

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."

Safety notes

1.4 Electromagnetic fields in electrical power engineering installations

Applications for Cabinet Modules, liquid cooled

16 Operating Instructions, 04/2015, A5E35974555A

Siemens SINAMICS S120 Operating Instructions Manual

Siemens SINAMICS S120 Operating Instructions Manual

Siemens SINAMICS S120 Operating Instructions Manual

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