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Sinamics Perfect Harmony Gh150
Sinamics Perfect Harmony Gh150
Installation Instructions
Medium-Voltage Drive
Safety instructions 2
Description 3
Medium-Voltage Drive
Preparations for use 4
SINAMICS PERFECT HARMONY
GH150 5
Assembly
Type 6SL3825
Electrical connection 6
Operating Instructions
Installation Instructions
Commissioning 7
Operation 8
Maintenance 9
Spare parts 10
Disposal 11
Quality documents C
Additional documents D
Edition 05/2020
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.
1 Introduction.................................................................................................................................................13
1.1 About these instructions.........................................................................................................13
2 Safety instructions ......................................................................................................................................15
2.1 Warning symbols on the device .............................................................................................15
2.2 Qualified personnel ................................................................................................................15
2.3 The 5 safety rules...................................................................................................................15
2.4 Safe handling .........................................................................................................................16
2.5 Electromagnetic fields in electrical power engineering installations ......................................18
2.6 Components that can be destroyed by electrostatic discharge (ESD)...................................19
2.7 Information for persons responsible for plants and systems..................................................20
2.7.1 Proper usage..........................................................................................................................20
2.7.2 Grounding concept.................................................................................................................21
2.7.3 Installation site safety.............................................................................................................21
2.7.4 Measures for operator protection in electromagnetic fields ...................................................22
2.7.5 Requirements for the circuit breaker provided by the customer.............................................22
2.8 Residual risks.........................................................................................................................23
2.9 Security information ...............................................................................................................25
3 Description..................................................................................................................................................27
3.1 Area of application .................................................................................................................27
3.2 Safety concept .......................................................................................................................27
3.2.1 Safety components and functions ..........................................................................................27
3.2.2 External safety components...................................................................................................28
3.2.3 Protection and monitoring functions of internal components .................................................28
3.2.4 Protection and monitoring functions for external components ...............................................28
3.3 Design ....................................................................................................................................29
3.4 Control Module.......................................................................................................................30
3.5 Basic Line Module..................................................................................................................30
3.6 Motor Module employing M2C technology.............................................................................30
3.7 Re-cooling unit ......................................................................................................................32
3.7.1 Cooling unit requirements ......................................................................................................32
3.7.2 Operating principle of the re-cooling unit ...............................................................................33
3.7.3 The internal deionized water circuit........................................................................................33
3.7.4 The external raw water circuit ................................................................................................34
3.8 Components...........................................................................................................................35
3.8.1 Control Unit ............................................................................................................................36
3.8.2 Power Stack Adapter .............................................................................................................36
5 Assembly ....................................................................................................................................................61
5.1 Safety instructions for assembly ............................................................................................61
5.2 Tools required ........................................................................................................................62
5.3 Screwing the transport units together ....................................................................................63
5.4 Connect to the foundation ......................................................................................................64
5.5 Connecting cabinets...............................................................................................................65
5.5.1 Connecting the interface cable...............................................................................................65
5.6 Connecting the water circuits .................................................................................................66
6 Electrical connection...................................................................................................................................69
6.1 Safety instructions for electrical connections .........................................................................69
6.2 Electromagnetic compatibility.................................................................................................71
6.3 Potential concept....................................................................................................................74
6.4 Cable cross-sections..............................................................................................................74
6.5 Connecting ground.................................................................................................................75
6.6 Laying the signal lines............................................................................................................76
6.7 Connecting the auxiliary voltage ............................................................................................77
6.8 Connecting power cables.......................................................................................................77
6.8.1 Preparations...........................................................................................................................77
6.8.2 Procedure...............................................................................................................................79
6.8.3 Shield connection...................................................................................................................79
6.9 Connecting the re-cooling unit to the drive.............................................................................80
6.10 Interconnecting optional connections.....................................................................................80
6.11 Fastening the cable ducts with cable ties...............................................................................81
7 Commissioning ...........................................................................................................................................83
7.1 Commissioning.......................................................................................................................83
7.2 Safety instructions for commissioning....................................................................................83
7.3 STARTER software................................................................................................................84
8 Operation....................................................................................................................................................85
8.1 Safety instructions for operation.............................................................................................85
8.2 Operating the converter .........................................................................................................86
8.3 Functions................................................................................................................................86
8.3.1 Monitoring functions and protective functions ........................................................................86
8.3.1.1 Insulation monitoring ..............................................................................................................87
8.3.1.2 Tripping of the circuit-breaker in case of undervoltage ..........................................................88
8.4 Fault and system messages ..................................................................................................88
8.4.1 Indicating and rectifying faults................................................................................................88
8.4.2 Diagnostics via LEDs .............................................................................................................89
8.4.2.1 LEDs of the Power Stack Adapters........................................................................................89
Tables
Figures
Note
The note provides you with additional information about the product itself, handling the product
- and the relevant documentation.
Please observe the warning symbols attached to the device. The warning symbols have the
following meaning:
General warning symbol: Observe the explanations about the hazard on the
device labels.
For transportation, observe the "transportation markings (Page 49)" on the device packaging.
5 safety rules
1. Disconnect the system.
Also disconnect the auxiliary circuits, for example, anti-condensation heating.
2. Secure against reconnection.
3. Verify absence of operating voltage.
Danger to life as a result of high voltages at the capacitors and in the DC link
High voltages are still present at the capacitors of the power cell and at the DC link even after
the system has been shut down. Touching live parts can result in death or serious injury.
● A label on the drive specifies the discharge times of the DC link capacitors. Only open the
drive once these discharge times have elapsed.
● Observe the five safety rules when performing any work.
Data loss
Electromagnetic fields can cause data loss to magnetic or electronic data storage media.
● Therefore, do not carry magnetic or electronic data storage media with you.
Persons responsible for plants and systems can find additional information on electromagnetic
fields under "Information for persons responsible for plants and systems (Page 20)."
ESD guidelines
G G G
E E
H H
I I I I I
F D F D F D
Danger to life when not complying with proper use of the devices
Improper use of the devices described can result in death, severe injury or material damage.
● Please observe all instructions for proper use.
The nominated person in control of an electrical installation must ensure that the following
points are observed:
● Follow the local and industry-specific safety and setup regulations. Observe the
requirements in the guidelines specified in the "Standards and regulations" section of the
"Technical data and drawings." Ensure that the specific safety and construction regulations
and the regulations for using personal protective equipment are observed during all work.
● The operating instructions and the complete product documentation are always available
when carrying out any work.
● The technical data as well as the specifications relating to the permissible installation,
connection, ambient and operating conditions are taken into account at all times.
● Only qualified personnel or personnel supervised by responsible, skilled specialists are
allowed to carry out basic planning and all work on the device.
● During shipping, specific transport conditions are adhered to.
● Assembly is performed according to assembly instructions. Separate cabinet units are
connected properly (cables and busbars).
● All instructions for EMC-compatible installation, cabling, shielding, grounding, and for
adequate auxiliary power supply are to be observed.
● Commissioning is only to be performed by qualified personnel trained for that purpose in
accordance with the commissioning instructions.
● System configuration is carried out by an experienced system integrator. Additional system
components - such as circuit-breaker, transformer, cables and motor - are coordinated and
harmonized with one another for drive operation.
Note
The drive does not have a grounding breaker at the input/output. The system operator must,
therefore, ensure that there is sufficient grounding.
WARNING
High voltages and arcs
Circuit breakers are safety components. Connecting or setting the circuit breaker incorrectly
can result in death, serious injury, or material damage.
Connect the circuit breakers correctly. Select the system values that match the drive.
To ensure adequate drive protection, the circuit breaker provided by the customer must fulfill
the following requirements:
● The total opening time of the circuit breaker – from the command to actually opening – must
not be more than 80 ms. It is not permissible that the opening time, specified in the technical
documentation of the circuit breaker manufacturer, exceeds 80 ms. The drive monitors the
total opening time.
● The drive monitors the TRIP coils (shunt releases) for wire breakage and failure of the
control voltage in the switchgear installation.
● The circuit breaker must be equipped with an undervoltage tripping function. The
undervoltage trip unit (low-voltage coil) is controlled via the tripping circuit in which the
"undervoltage trip unit" of the drive must also be integrated. The auxiliary voltage from the
switchgear (this is a reliable supply) is used as the supply.
● Avoid additional delay times when controlling the circuit breaker. All commands from the
drive to the circuit breaker must act directly without intervention of coupling relays.
● A feedback signal must be available for each of the circuit breaker states CLOSED and
OPEN. The feedback signals must not be delayed. Do not use any coupling relays.
● An additional, independently operating overcurrent protection for the circuit breaker must be
provided on the plant side (transformer and cable protection).
● The circuit breaker is activated and enabled by the drive closed-loop controller. Under no
circumstances should you close the circuit breaker by external mechanical or electrical
means. A mechanical interlock of the manual ON command at the circuit breaker prevents
destruction of the drive as a result of an uncoordinated switch-on operation.
● Damage from pressure build-up during electric arcs in the event of a fault
If the building has not been designed correctly in terms of how it has been dimensioned,
damage can result from the pressure that can possibly build up inside.
● Dangerous electric arcs during internal faults
The devices have been designed according to the relevant IEC standards, and tested in line
with strict type-testing procedures. They were developed and manufactured so that there is
a very low probability of internal faults occurring. However, internal faults cannot be
completely ruled out.
WARNING
Dangerous electric arcs during internal faults
Defects such as damage to components, overvoltages, or loose parts, as well as exceptional
operating statuses, can cause a failure within the enclosure. This can result in an internal
electric arc. If an electric arc occurs and people are nearby, this could lead to death, serious
physical injury, and damage to property.
● Ensure that only qualified personnel perform any work that is required.
● Observe the safety and operating instructions in this documentation and labels attached to
the device for any work that is performed.
Notes relating to Industrial Security for HMI devices are available here.
(https://support.industry.siemens.com/cs/de/en/view/109481300)
Note
Please refer to Chapter "Technical data and drawings" for the converter power range.
The device and its associated components are subject to an extensive safety concept. When
used properly, the security concept guarantees safe installation, safe operation as well as safe
service and maintenance.
The safety concept encompasses safety components and functions to protect the device and
operators. The device is also equipped with monitoring functions to protect external
components.
The device operates safely when the interlock and protection systems are functioning properly.
Nevertheless, there are areas that are hazardous for personnel and that cause material
damage if the safety information of all the instructions and the labels on the device are not
strictly complied with.
The door interlocking system prevents access to the power unit while operational. The following
conditions must be fulfilled in order to open the doors: For additional information, see Chapter
"Opening the device (Page 94)".
The internal components of the drive have the following protection and monitoring functions:
● Drive protection based on monitoring systems:
– Current monitoring
– DC link monitoring
– Monitoring the output voltage
– Thermal monitoring of the power unit
– Precharging monitoring
– Supply voltage monitoring
– Insulation monitoring
– Monitoring of the common power supply
– Circuit breaker monitoring
– Re-cooling unit monitoring
● Shutdown in the event of semiconductor failure
● Shutdown in the event of control component failure
● Internal protection functions for the control hardware
● Protection against communication failure between the closed-loop control and the power
unit
3.3 Design
The drive in the basic configuration is equipped with the following components:
● A Basic Line Module (12-, 18-, 24- or 36-pulse)
● A Motor Module deploying M2C technology
A Braking Module in M2C technology is optionally available.
ʪ
ʪ
The purpose of the Control Module is for the open-loop and closed-loop control of the drive.
Operating control and diagnostics of the drive are also realized using the Control Module.
Note
Details on the design can be found in the layout diagram.
Basic Line Modules generate a DC voltage and thus provide the energy for the modules
connected to the DC link. In this case, the line voltage fluctuations must remain within the
permissible tolerance range. Depending on the design, the Basic Line Module consists of
series-connected six-pulse rectifiers. In order to limit the short-circuit currents per unit, the
Basic Line Modules are constructively divided into multiple cabinets. RC combinations are
provided to protect the diodes.
Note
Details on the design can be found in the layout diagram.
The Motor Modules provide the power for the connected motor. The Motor Module is supplied
with power for the motor via the DC link.
The Motor Module is built in M2C technology with IGBT semiconductors. Motor Modules in
M2C technology provide the motor with almost sinusoidal voltages. The Motor Module in M2C
technology comprises a submodule and a branch reactor cabinet.
● The power cells are housed with the IGBT semiconductors in the submodule cabinet.
● The branch reactors and the associated measuring equipment can be found in the branch
reactor cabinet.
The inverter unit has three phases. Each phase comprises two so-called M2C branches. The
six branches of the M2C inverter each consist of identical power cells connected in series. The
phase of the voltage-source DC link drive is realized employing M2C technology using power
cells connected in series for two branches.
Note
Details on the design can be found in the layout diagram.
See also
Power cell (Page 38)
The internal water circuit is filled with deionized water (deionized, fully-desalinated water). The
conductivity of the cooling water must be ≤ 1 µS/cm in operation.
NOTICE
Material damage due to inadmissible additives in the deionized water
Inadmissible additives in the deionized water can cause the cooling system to fail. This could
damage the drive.
● Use only deionized water that corresponds to the specifications. The specification of the
deionized water can be found in the documentation for the re-cooling unit.
● The level in the deionized water expansion tank and the pump motor circuit breakers are
monitored. Any water leak is also detected.
● The pressure of the deionized water is displayed on a manometer. If the flow is excessively
low, then the re-cooling unit automatically switches over the pumps.
● The deionized water temperature is measured. The value is used for controlling the three-
way valve
● If one of the monitoring devices responds, a signal is output or the re-cooling unit and drive
are switched off.
Value
Conductivity during filling < 10 μS/cm
Evaporation residue < 20 mg/l
pH value 5 to 9
Value
● Content of metals in the hydrogen sulfide group (lead, antimo‐ Not detectable
ny, tin, bismuth, arsenic, copper, cadmium)
● Content of metals from the ammonium sulfide group (iron, co‐
balt, nickel, chrome, manganese)
● Content of sulfur chloride and nitrogen compounds
Content of oxidizable, organic substances Max. a quantity equivalent to the
usage of 30 mg/l potassium per‐
manganate KMnO4
Ion exchanger
An ion exchanger is installed in the re-cooling unit. The ion exchanger is connected in the
deionized water circuit.
If the conductivity exceeds the permissible limits, then a message is output. In this case,
replace the filling in the ion exchanger with an original filling. If the conductivity continues to rise,
the re-cooling unit and drive are switched off. The ion exchanger is a consumable and is not
covered by the warranty.
Dirt filters
The re-cooling unit is equipped with several dirt filters
● A dirt filter with a sieve (mesh width: 0.5 mm) is located in front of the drive intake.
● A fine filter (mesh width: 0.05 mm) is located at the ion filter outlet.
● An air filter is fitted on the expansion tank.
that filter out dirt and contamination from the water circuit, thereby preventing the drive from
being damaged.
The raw water flows through the heat exchanger. The heat exchanger cools the deionized
water.
If other raw water specifications apply, titanium heat exchanger plates or tube bundle heat
exchangers are available (optional).
NOTICE
Material damage caused by deposits of suspended solids
If you reduce the flow rate to reduce the raw water usage, then deposits of suspended solids
can build up in the heat exchanger as a result of the slow flow rate.
These suspended solids can then cause the cooling system to fail. The drive could be
damaged.
Only reduce the raw water flow rate if the raw water does not have any suspended solids.
Value
Size of entrained particles < 0.5 mm
pH value 6.5 to 8.0
Carbonate hardness < 0.9 mMol/l (5 °dH)
Total hardness < 1.7 mMol/l (9.5 °dH)
Chloride 60 mg/l
Sulfate 80 mg/l
Nitrate 10 mg/l
Core 0.2 mg/l
Ammonia 10 mg/l
Dissolved solids <3.4 mMol/l (340 ppm)
Where values deviate from the above stated, a water analysis should be carried out in order to
ensure the long-term stability of the heat exchanger.
3.8 Components
The CU320-2 PN Control Unit is the central control module of the drive's open-loop and closed-
loop control system. The connections are wired internally to the customer terminal block.
The Power Stack Adapter (PSA) acts as the physical interface between the power unit and the
open-loop/closed-loop controller. This is where the galvanic isolation (electrical coupling via
light) between the power unit and the open-loop controller takes place. Data is exchanged
between the Power Stack Adapter and the Control Unit via the DRIVE-CLiQ high-speed serial
communication interface.
See also
DRIVE-CLiQ interface (Page 46)
LEDs of the Power Stack Adapters (Page 89)
The Terminal Modules are the central interface for digital and analog inputs and outputs. You
can optionally expand the interface to include additional Terminal Modules.
A power cell comprises the following mechanical units that can be separated:
● IGBT module
● Capacitor bank
① IGBT module
② Capacitor bank
Figure 3-5 Power cell
See also
Replacing a power cell (Page 109)
For M2C topology, a low-inductance busbar is only required within the power cell. The control
electronics takes its power from the capacitor bank. The gating electronics is mounted directly
above the IGBT modules, and therefore guarantees a compact design with high noise
immunity.
The power semiconductors are connected via the gating electronics. The gating command is
transmitted from the power stack adapter (PSA) to the gating electronics via a plastic fiber-optic
cable connection.
See also
Opening the device (Page 94)
3.8.7 Precharging
The power cell capacitors must be precharged in order to avoid overcurrents and temporary
overvoltage conditions in the DC link when connecting the line supply. The DC link is
precharged via the auxiliary supply.
The precharging circuit comprises the following components:
● Precharging transformer
● Diode bridge
● Precharging resistors
● Contactor for switching on and off
● Circuit-breaker
Detailed information about interconnecting the precharging components is provided in the
circuit manual. The component mounting locations are provided in the layout diagram.
See also
Replacing the AVT combination module (Page 105)
Replacing the current transformer (Page 106)
switches itself off automatically in the event of a short-circuit at one of the power outputs. The
associated LED of the affected power output lights up red until the short-circuit has been
rectified and the device is back in proper working order. This requires that the upstream
miniature circuit-breaker is opened and after approximately 10 seconds is closed again.
3.8.9.2 Connections
;
,$! ;
;
;
8$
;
;
;
;
;
;
Connector Task
X1 Line connection
X2 Signaling
X6 / X7 / X8 / X9 Power output
Connector/pin Signal
X1.3 L
X1.4 Not assigned
X1.5 N
X1.6 Not assigned
X1.7 PE
X2.4 Undervoltage REL_A
X2.5 Undervoltage REL_B
X2.6 Presence of output voltage REL_A
X2.7 Presence of output voltage REL_B
X6.1 / X7.1 / X8.1 / X9.1 PE
X6.2 / X7.2 / X8.2 / X9.2 P-GRD
X6.3 / X7.3 / X8.3 / X9.3 ± 55 V
Line filters are used to suppress interference in the auxiliary power supplies. Information about
the connection of the line filters is contained in the circuit manual. The mounting location is
provided in the layout diagram.
safety relay and the external contactors are monitored to ensure that they are functioning
correctly.
See also
Connecting the auxiliary voltage (Page 77)
3.9 Interfaces
See also
Connecting the water circuits (Page 66)
See also
Laying the signal lines (Page 76)
WARNING
Danger to life as a result of unsafe operation
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.
Figure 4-1 Example of attaching and displaying the shock and tilt indicators
WARNING
Danger to life as a result of damaged load suspension devices and lifting gear
If the load suspension devices and lifting gear are damaged or not correctly secured, then
the equipment may fall while being lifted and transported. This can result in death, serious
injury or material damage.
● Inspect the load handling attachments and lifting gear before use.
4.3 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
Top Fragile material Keep dry Keep cool Center of Do not use Attach here
gravity hand hook
NOTICE
Material damage caused by vibration
Significant vibration during transportation and shocks when setting down can damage the
equipment.
● Avoid vibrations and shocks.
WARNING
Danger to life if center of gravity specifications are not strictly observed
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 transport
unit that defines 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.
)URQWYLHZ 6LGHYLHZ
WARNING
Danger when a transport unit/cabinet tips over
If the forks are too short, this can cause the transport unit/cabinet to tip over resulting in death,
serious injury, or damage to the cabinet.
● The forks of the truck must protrude at the rear of the transport pallet. The floor panels of
the transport units will not support a load.
● Only use fork-lift trucks approved for this purpose to transport the units.
When the transport units are transported or moved with a fork-lift truck, the force is absorbed
through the transport pallet.
Observe the following points for safe transport:
● Transport the transport unit/cabinet with the greatest care.
● Choose the lowest transport height possible. The pallet may not touch the ground. Always
transport the cabinet in an upright position.
● Avoid driving over bumps.
WARNING
Danger due to incorrect transport
If the transport unit is not properly transported with a crane, the transport unit/cabinet could fall
or tip over This can result in death, serious injury or material damage.
● Carefully comply with the safety instructions relevant for transport.
● Carefully observe the information regarding the center of gravity on the transport unit.
WARNING
Danger due to unsuitable cross-arms
If inappropriate cross-arms are used, the transport unit or cabinet can tip over. This can result
in death, serious injury or material damage.
● Observe the specifications provided in DIN EN 13155 on cross-arms.
When transporting by crane, note that the force is applied via the transport rails attached to the
bottom of the cabinet.
Note
Lifting bars
The lifting bars are not included in the scope of delivery.
WARNING
Danger if the device falls
Inadequately dimensioned lifting rods are liable to bend or break. As a consequence, the
device can fall from the crane. This can result in death, serious injury or material damage.
● Use suitable lifting rods for transporting. The weight of the cabinet is indicated on the rating
plate.
NOTICE
Material damage to the drive when incorrectly lifted
If the transport unit is lifted incorrectly, this can damage the decorative trim, cabinet doors, or
fans.
● Protect the cabinet and protruding parts against damage.
● Always lift the transport units with the appropriate spreading devices or hoisting tackle.
Procedure
1. If there are several holes, select which holes to use based on the center of gravity.
2. Push the lifting bars through the holes.
3. Place the sling ropes on the lifting bars so they are close to the cabinet. Secure the ends of
the lifting bars using the splint.
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.
WARNING
Danger when a transport unit/device tips over
If the forks are too short, this can cause the transportation unit/the device to tip over resulting
in death, serious injury, or damage inside the cabinet.
● The forks of the truck must protrude at the rear of the transportation unit.
● Only use forklifts approved for the purpose of transporting the devices.
WARNING
Danger due to falling transport unit/cabinet
If the lifting gear or load suspension devices were to fail, the transportation unit/the cabinet
could fall. Death, serious injury, or material damage can result.
● Do not stand underneath or near to a raised load.
To protect the boxes against pressure, use sufficiently long rope and a spreader beam. Please
proceed as follows:
1. Attach the rope/cable to the pallet as shown in the following diagram.
2. Attach the rope/cable to the spreader beam ① and the crane hook.
3. Pay attention to the center of gravity imprinted on the box ② and the imprinted position of
the ropes ③.
4. Carefully raise the transportation unit.
① Spreader beam
② Center of gravity
③ Imprinted position of the rope
Figure 4-5 Transporting a transportation unit (still in packaging) with a crane
See also
Transport with a fork-lift truck (Page 50)
Transport with a crane (Page 51)
Refer to the operating instructions of the re-cooling unit for notes relating to transport and
storage.
NOTICE
Damage to the ion exchange cartridge as a result of frost
If the ion exchange cartridge is exposed to frost, it may be damaged.
● Only transport and store the ion exchange cartridge in non-frosty conditions. More
information is available in the re-cooling unit's operating instructions.
NOTICE
Material damage caused by incorrect storage of unpacked equipment
Proper packaging ensures that the equipment is protected. Unpackaged equipment may be
damaged if it is stored or out of service over a long period.
● Carefully comply with the instructions for storage in Chapters "Storage" and "Technical
data and drawings".
● Remove the packaging immediately prior to installation.
The units are packed by the manufacturers in accordance with the order.
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.
WARNING
Danger to life as a result of fixing materials under tension
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
Material damage caused by incorrect removal of a load securing device
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.
NOTICE
Damage to the locking mechanism caused by incorrectly opening the doors
You can damage the locking mechanism if you open the doors incorrectly.
● When opening the doors, follow the steps described.
● If the locking mechanism is damaged it is essential that you have it repaired before
commissioning the drive system. If this is the case, then contact the Service Center. You
can find the relevant contact persons at "Service & Support".
The drive is delivered in a closed state. A label showing how to open the doors in a current-free
state is located on the door.
Figure 4-6 Example: Label with instructions for opening the doors
Proceed as follows:
1. There is a screw in the door. Under the screw you will find the opening for manually opening
the doors. Remove the screw.
2. Insert a screwdriver into this opening.
4.4.5 Checking the shock and tilt indicators inside the cabinet.
Shock and tilt indicators are also located inside the cabinet. Check these as soon as you have
unpacked and opened the device. To perform the check, proceed as described in "Checking
shock and tilt indicators"
NOTICE
Material damage caused by shipping indicators remaining in the device during operation
During operation, the shipping indicators can become detached and fall into the device as a
result of high temperatures. Material or temperature damage may result.
● Remove the shipping indicators before commissioning. Remove any adhesive residue
from the shipping indicators using methylated spirits.
See also
Checking shock and tilt indicators (Page 47)
4.5 Storage
NOTICE
Frost damage or corrosion as a result of the coolant
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.
● Before storing the device completely drain the cooling system.
● 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 again,
empty the drive completely prior to storing it. 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
Damage caused by excessively high blow-out pressure
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.
NOTICE
Damage to the device as a result of incorrect 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.
NOTICE
Diminished fan function if the fan is incorrectly stored
Even if the fan is not used, the bearing grease ages. The utility of the fan can be impaired.
● Rotate the fan at least once a year.
● Do not store the fan for longer than two years before commissioning.
Refer to the operating instructions of the re-cooling unit for notes relating to transport and
storage.
NOTICE
Damage to the ion exchange cartridge as a result of frost
If the ion exchange cartridge is exposed to frost, it may be damaged.
● Only transport and store the ion exchange cartridge in non-frosty conditions. More
information is available in the re-cooling unit's operating instructions.
See also
Opening the device (Page 94)
NOTICE
Material damage caused by mechanical pressure on components
Stress that occurs during transport may exert mechanical pressure on the components.
Material damage can result.
● Line the cabinets up precisely with each other in order to avoid shearing forces when the
base units are screwed together.
● Install the converter only on a level and horizontal surface.
Preparation
Ensure that access to the holes in the bottom of the cabinets is unobstructed. Remove the
guard covers.
To screw the transport units together, you will need the following mounting hardware:
● Hexagon nuts ISO 4032-M8-8 A2L
● Contact washers SN70093-8-FSt-mechZn-f
● Threaded pin M8 x 15.5
● Self-adhesive sealing strips
3. Insert the threaded bolts through the holes ②. Use the holes in the corners and then every
300 mm.
DANGER
Danger due to failure of the protective and monitoring equipment
The converter must be grounded to ensure that it operates safely and reliably. If the converter
is operated with insufficient grounding, then the protection and monitoring functions can fail.
Death, serious injury, or material damage will result.
● Always apply all of the necessary protective measures.
● Always observe the five safety rules when working with the converter.
● Follow these steps when grounding the machine:
– Establish the connections in a cabinet.
– Ensure that the connections are also established over several cabinets.
– Establish the ground connection for the whole plant immediately.
If several cabinets are set up as one unit, the grounding connections of the individual cabinets
must be connected with each other. A grounding lug connection cable is supplied with each
cabinet. To connect the ground connections for several cabinets, proceed as follows:
1. Insert the grounding cable ① through the side panel of the cabinet.
2. Secure the grounding cable on the grounding lug ② with an M12 screw.
3. Tighten the screw with a torque of 50 Nm.
Route the interface cables ② through the openings ①. Connect the cabinet interface sockets
using cables as shown in the circuit diagram. Route the fiber-optic cable carefully without
kinking the cable.
Detailed information is provided in the converter circuit diagram.
CAUTION
Eye and skin injuries caused by deionized water
Deionized water is harmful to eyes and skin and can damage surfaces.
● Therefore, use appropriate protective clothing for all work on the drive. However, if your
eyes or skin do come into contact with deionized water, rinse the affected area thoroughly
with tap water as soon as possible.
● If deionized water leaks out, eliminate the source of the problem and remove the liquid from
the surfaces affected.
NOTICE
Overheating caused by foreign bodies in the cooling system
Foreign bodies in the cooling system can cause blockages in individual circuits. As a result,
the water-cooled components overheat and the drive fails.
● For this reason, make sure that no foreign bodies can enter the water circulation system.
● Only remove the protective cover immediately prior to connecting the water circuit.
① Inlet (blue)
② Return (red)
③ Union nut
Figure 5-4 Water piping
To establish the connection of the raw water circuit, observe the details in the dimension
drawing.
See also
Opening the device (Page 94)
Note
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.
Note
We recommend using shielded cables. Unshielded cables can transfer disturbances to the
control and signal lines and lead to malfunctions in the drive.
Note
To ensure trouble-free operation without interference or disturbances, route the power cables
and signal lines separately. Interference, for example, will result in the device not behaving as
expected.
When connecting and routing power and signal cables, observe the instructions provided in
chapter "Electromagnetic compatibility (Page 71)".
Note
We recommend that EMC is planned for the entire plant.
Cabinet installation
● Connect painted or anodized metal components using contact washers or remove the
insulating layer.
● Use unpainted, de-oiled mounting plates.
● Establish a central connection between ground and the protective conductor system (PE
protective conductor).
Cable installation
● Cables that are subject to or sensitive to interference should be laid as far apart from each
other as possible.
● The distance between the power cable and the signal cable should be at least 20 cm.
Device-specific data apply for power cables. You can find further information on power
cables under "Connecting power cables".
● When the cables are routed close to ground potential, the immunity to interference is
increased. For this reason, you are advised to lay these cables along edges and at ground
potential.
● Ground the reserve cores on at least one end.
● In order to avoid additional locations where interference can be coupled in, long cables
should be shortened or routed where there is little interference.
● If conductors or cables conduct signals of different classes, then the conductors and cables
must cross at a right angle. This especially involves sensitive and noisy signals.
– Class 1:
Unshielded cables for ≤ 60 V DC
Unshielded cables for ≤ 25 V AC
Shielded analog signal cables
Shielded bus and data cables
Operator panel interfaces, incremental/absolute encoder cables
– Class 2:
Unshielded cables for > 60 V DC and ≤ 230 V DC
Unshielded cables for > 25 V AC and ≤ 230 V AC
– Class 3:
Unshielded cables for > 230 V AC/V DC and ≤ 1000 V AC/DC
– Class 4:
Unshielded cables for > 1000 V AC/DC
Shield connection
● Do not use cable shields to conduct current. It is not permissible that the cable shield is used
as neutral or PE conductor.
● Apply the cable shield so that it covers the greatest possible surface area. Use ground
clamps, ground terminals or ground screw connections.
● Avoid extending the cable shield to the grounding point using a wire. This reduces the shield
effectiveness by up to 90%.
● Attach the cable shield to a shield busbar directly after the line inlet into the cabinet. Insulate
the shielded cable without any interruptions. Route the cable shield up to the device
connection.
① Shield busbar
② Shielded cable
③ Mounting clip
Figure 6-1 Shield connection using a clip
NOTICE
Impaired functionality as a result of damaged or incorrectly connected cable shields
Incorrect connection or damaging of the cable shield can impair the function of the system.
● Handle the cable shield carefully.
● Ensure that the cable shield is correctly connected.
● Bridge shield gaps (at terminals, circuit-breakers, contactors, etc.) with minimum
impedance and through the largest possible surface area.
① Shield busbars
② Cables
③ Terminals
Figure 6-2 Bridging shield gaps
I/O connection
● Create a low-impedance ground connection for additional cabinets, system components,
and distributed devices with the largest possible cross-section (at least 16 mm²).
● Ground unused lines at one end in the cabinet.
● Choose the greatest possible clearance between the power and signal cables (at least 20
cm). The greater the distance over which the cables are routed in parallel, the greater the
clearance must be. You must install additional shields if sufficient clearance cannot be
maintained.
● Avoid unnecessarily long cable loops.
● Surge suppressors – e.g. RC elements or varistors – must be connected to the solenoids of
contactors and relays in the device.
● In order to reduce noise/interference entering or exiting via the cable, filter auxiliary voltages
in the control cabinet.
3
1 3
0 0
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ORDGV ORDGV
See also
Torques (Page 103)
DANGER
Danger to life as a result of insufficient grounding
The drive must be grounded to ensure that it operates safely and reliably. If the drive is
operated with insufficient grounding, then the protection and monitoring functions can fail.
Death, serious injury, or material damage will result.
● To ensure the correct functioning of the protection and monitoring equipment, ground the
device.
A grounding busbar is located in the lower section of the cabinets ②. The grounding busbar is
used to ground the components installed in the cabinet and to ground the cabinet itself.
1. To ensure safe drive operation, connect a protective grounding conductor ④ to the
grounding busbar ②.
2. Connect the grounding cable of the foundation ③ to the grounding busbar ②.
① Foundation
② Grounding busbar
③ Grounding cable
④ PE protective conductor
Figure 6-4 Connecting_grounding cable
Note
For more information, see the interconnection diagram in the circuit manual.
See also
Electromagnetic compatibility (Page 71)
See also
Technical data and drawings (Page 135)
6.8.1 Preparations
When connecting the cables, observe all the conditions regarding conductor protection. Do not
exceed the permitted cable lengths between the converter output and motor. The distance
between the motor cable and the signal cable should be at least 20 cm. Do not lay grid-side and
motor supply cables in parallel to each other.
The positions of the connections are shown in the layout diagrams. Detailed wiring notes for the
converter are contained in the circuit manual of the converter.
Select the appropriate cable depending on the following conditions:
● Routing conditions
● Accumulation of cables
● Ambient temperature
● Bending radii
● Output voltage
Observe the connection capabilities on the converter and on the motor terminal box.
Detailed information about cabling of the converter is provided in the circuit diagrams supplied.
● Please ensure that the maximum cable lengths between the converter and motor are not
exceeded.
● Make sure that the permissible cable capacitance is not exceeded.
● Use appropriate screws for the cable lugs provided.
● The tightening torque for the M12 screws is 50 Nm.
● Clean the contact surfaces before screwing the connections.
● Apply a thin layer of grease to the screws.
Materials required
Cleaning agent Ethyl alcohol
Grease 2G from Elektrolube
NOTICE
Thermal destruction of the power cable
Cables that have not been properly secured at the connection point, represent a high electrical
transition resistance, which can result in thermal destruction.
● Tighten the screws with the specified torques (Page 103).
6.8.2 Procedure
To connect the power cables, proceed as follows:
1. Open the cabinet.
2. If there is a controller rack, swing it out of the way.
3. Remove or slide away the cover plate for the power cable entry.
4. Screw the PE protective conductor with an M12 screw at the locations ④ provided in the
cabinet to the appropriate connection with the ground symbol. Observe the torque of 50 Nm.
On this topic, take note of section "Connecting ground (Page 75)".
5. Screw the individual phases of the power cables ① with the connections in the lower area
of the cabinet. To do this, follow the subsequent steps.
6. Insert the M12 screw into the corresponding terminal bar ②.
7. Attach the cable lug.
8. Attach the nuts and, if necessary, the washers. Tighten the nuts with a torque of 50 Nm.
9. Expose the cable shield. Secure the cable on the cable support bar using cable clips ③.
Procedure
7UDQVI 'ULYH 6SHHGHQFRGHU 0RWRU
&8
&DEOHWUD\
6KLHOGEXVEDU
&DEOHGXFW
&DEOHWUD\
1 Shield connection
2 Cable gland with grounding bushing
Figure 6-6 Shield connection
Input side
Only connect shield 1 on the drive side to the PE shield busbar. Do not connect the shield on
the transformer side.
Output side
Connect shield 1 at the drive to the PE shield busbar. Connect shield 2 at the motor.
When carrying out any work, carefully observe the information provided in Chapter "Safety
instructions (Page 15)".
● Commissioning
● Testing
● Drive optimization
● Diagnostics
The STARTER software is available in SIOS under the following link:hot‐
spot text (https://support.industry.siemens.com/cs/ww/en/view/26233208)
Note
To complement these operating instructions, the List Manual contains an overview of all
parameters as well as a selection of function diagrams to describe the operating principle.
8.3 Functions
Note
List manual
References to functions, function plans, and parameters are found in the list manual for the
drive.
The drive features hardware and software functions that protect it against faults and damage
caused by impermissible operating statuses or hardware malfunctions. The monitoring
elements provide internal microprocessor-controlled monitoring and remote device monitoring.
The drive is operated in an ungrounded IT supply system. This means that the drive can
continue to operate if just one ground fault occurs.
Note
A second ground fault causes the drive to fail.
For safety reasons, it is necessary to detect such ground faults, in order to eliminate the risk of
electric shock on the drive. This is the reason why the drive is equipped with insulation
monitoring (A-Isometer) that continually monitors the insulation state of the drive including that
of the motor.
Only one A-Isometer can be connected to each live connected IT system. The A-Isometer
adjusts monitoring in line with the line discharge capacitance. The A-Isometer is connected
between the ungrounded line supply and the equipotential bonding conductor (PE).
For the duration of testing, disconnect the instrument cables of the A-Isometer when performing
any insulation or voltage testing on the power system.
Self-test
The A-Isometer performs an automatic self-test under the following conditions:
● When the insulation resistance of the line supply > 20 MΏ
● Every 24 hours when an output relay for the system error message has been preselected.
Terminal monitoring
The connections to mains and ground (PE) are monitored continuously. If the cables are
interrupted or not connected, or if their resistance is high, this is indicated on the LCD. In this
case, please check the terminal conductors immediately, as the insulation resistance is not
being measured properly.
The insulation resistance can be > 20 MΏ in new or small IT systems. To suppress the
message, disable the connection monitoring in Setup2. The A-Isometer monitors the insulation
resistance of the drive.
The following limit values are monitored:
● Limit value 1: Insulation resistance < 500 kΩ = Signal 1 (alarm)
● Limit value 2: Insulation resistance < 100 kΩ = Signal 2 (fault)
The signals are issued to STARTER and output on the operator panel. Further information
about the wiring is contained in the circuit manual.
WARNING
Danger to life as a result of residual voltages at the output terminals
This function cannot ensure that the drive stops immediately, nor can it ensure that residual
voltages do not still exist at the output terminals and within the device itself.
High voltages can cause death or serious injury if the safety rules are not observed or if the
equipment is handled incorrectly.
● Always carefully observe the "five safety rules (Page 15)".
The drive provides many protection functions. These protection functions protect the drive
against damage in a fault situation. A distinction is made between the following messages:
● Fault
A fault is a message from the drive indicating a fault or other exceptional (unwanted) state.
The cause can be a fault in the drive itself or also an external fault. This fault, for example,
could have been issued by the winding temperature monitoring of the asynchronous motor.
The faults are displayed and can be reported to a higher-level control system. Once you
have eliminated the cause of the fault, you must acknowledge the fault message.
● Alarm
An alarm is the response to a fault condition identified by the drive, that does not result in the
drive being shutdown. Alarms acknowledge themselves. If the cause is no longer present,
the alarms reset themselves automatically.
The converter indicates a fault by displaying the corresponding fault and/or alarm on the
operator panel.
Faults are displayed as follows:
● By illuminating the red LED "FAULT"
Additionally, a note relating to the cause of the alarm is displayed in the status bar of the
operator panel.
Press the <F1> "Help " key function to call up information about the cause and remedial
measures. Press the <F5> "Quitt." key to acknowledge a stored fault.
Alarms are indicated as follows:
● The yellow LED "Alarm" flashes
Additionally, a note relating to the cause of the alarm is displayed in the status bar of the
operator panel.
Every fault and alarm is entered in the fault/alarm buffer along with time the fault occurred. The
time stamp refers to the relative system time in milliseconds (r0969).
LED Operation
POWER CHANNEL1 CHANNEL2 Line supply EMERGENCY ON Release circuits
STOP
☀ ☀ ☀ On Not actuated Actuated Closed
☀ ○ ○ Actuated Not actuated Open
☀ ○ ○ Not actuated Not actuated Open
Fault
☀ ○ ○ ● Relay jammed Open
● Motor contactor jammed
● Defect in electronics
○ ○ ○ Cross-circuit/ground fault in EMERGENCY STOP
circuit/no supply voltage
Note
The actual intervals at which maintenance procedures are to be performed depend on the
environmental and operating conditions. Define maintenance intervals that reflect your plant-
specific environmental and operating conditions and meet your availability requirements. When
doing so, take the prescribed maintenance intervals into consideration, as well as the
instructions for repairing and replacing installed components.
Note
Siemens offers its customers support in the form of a service contract. For further details,
contact your regional office or sales office.
Note
Inform the manufacturer about each maintenance job that has been carried out and about each
spare part replacement for the purposes of a reliability analysis.
WARNING
Electric shock even after shutdown
High voltages can still be present even after shutdown. Touching the device can result in death
or serious injury.
● Only work on the power unit if it has been sufficiently grounded. Before touching the device,
carefully ensure that the power unit is in a no-voltage condition:
● Always observe the five safety rules (Page 15) when carrying out any work on the device.
1. Secure the terminal of the grounding harness to the lower fixed sphere ②.
2. Secure the terminals of the grounding harness to the upper fixed spheres ①.
The drive is equipped with a door interlocking system. Depending on the design, this is an
electromechanical door interlocking system or optionally a safety locking system.
The doors for the Control Module can be opened for monitoring purposes during operation.
WARNING
Danger to life although the door interlocking has been released
Even when the door interlocking is released, high voltages can still be present at the auxiliary
circuits (fans, anti-condensation heating, closed-loop control, etc.). Touching live components
can result in death or serious injury.
● Ensure that work is only carried out by qualified personnel.
● The five safety rules must be observed.
The doors cannot be opened until the following conditions are fulfilled:
● The converter is ready to switch on, or in the "switching on inhibited" state, no ON command
is active.
● The circuit breaker is open (feedback signal, "circuit-breaker OPEN").
● The "zero voltage criterion" in the DC link is fulfilled.
● The "zero voltage criterion" at the phase connection is fulfilled.
● None of the cell controls supplies status information.
The cell electronics no longer operate below a cell voltage of 200 V. As a consequence,
status information is no longer transferred to the control.
● The cell electronics no longer functions.
Up to the residual discharge (<5 V), the system waits for 5x the time constant of the
discharge resistor and cell capacitor. For the components being used, this results in a time
constant of at least 14 minutes.
WARNING
Danger to life even after shutdown
After shutdown, high voltages are present at the drive and its components. Furthermore, if the
connection to the machine or the line supply is not disconnected and grounded, these voltages
can persist. Touching live components can result in death or serious injury.
● Never force the doors open during operation or while the DC link capacitors are being
discharged.
● The five safety rules (Page 15) must be observed.
If the auxiliary voltage fails, you can only unlock the doors manually. To unlock the doors,
proceed as described in the chapter titled "Preparation for use".
9.4.1 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 ambient conditions at the location of use. The
following servicing and inspection instructions are used as the basis for regular inspection of
the equipment.
Note
The actual intervals at which maintenance procedures are to be performed depend on the
environmental and operating conditions. Define maintenance intervals that reflect your plant-
specific environmental and operating conditions and meet your availability requirements. When
doing so, take the prescribed maintenance intervals into consideration, as well as the
instructions for repairing and replacing installed components.
Regularly check the plug connections to ensure they are seated correctly and the contacts are
not corroded.
Note
The fiber-optic cables for the gating boards must be properly inserted in the connectors.
See also
The external raw water circuit (Page 34)
9.5 Maintenance
CAUTION
Injury caused by rotating fan
If the drive is equipped with a temperature-controlled fan, the fan can run on even if the power
section is switched off. You can be injured if you touch the fan.
● Wait until the fan has shut down and has come to a stop.
Figure 9-2 Replacing fans from the front
1. Remove the front cover from the fan box ①. To do this, remove the screws.
2. Loosen the connector of the fan connector cable from the terminal in the fan box.
3. Loosen the fastening screws of fan ②.
4. Pull the fan out of the fan box.
5. Release the connecting cable ③ at the fan.
6. Remove the two sheet-metal brackets ④ from the fan baseplate.
CAUTION
Risk of injury caused by a falling fan
The fans are heavy. The fans can fall if incorrectly handled. This can cause injury and
material damage.
● Please take special care when removing the fans from the drive.
CAUTION
The fan can fall
The fans are very heavy. They can cause injury or material damage if handled improperly.
Please take special care when removing the fans from the drive.
9.6 Cleaning
NOTICE
Damage caused by aggressive cleaning agents
Aggressive chemical agents can damage the electronics. This can result in malfunction.
Never use any type of chemical agent or liquid.
● Only remove severe dirt and contamination after prior consultation with service experts for
the particular product.
Use a dry, clean, lint-free ESD cleaning cloth. Wipe all external parts of the rack with it. Make
sure that the dirt is not distributed, but actually removed by constant changes of the wiping
surface of the cloth. For significant levels of pollution and dirt, use an ESD cloth soaked in ethyl
alcohol (however, not so much that it drips from the cloth).
NOTICE
Corrosion damage caused by unsuitable cleaning agents and cleaning instruments
Using unsuitable cleaning chemical agents and cleaning instruments may transfer
metallic, corrosion-inducing impurities onto the aluminum. This can result in corrosion
damage.
● Only use cleaning agents that are suitable for aluminum.
● Use ESD-compliant brushes and cloths.
● Do not use cleaning cloths and brushes that have already been used to clean copper,
brass, bronze or other heavy metals.
● Use neither brass, bronze, or steel-wire brushes nor cloths or steel wool interwoven
with copper wire.
9.7 Repair
When carrying out any work, carefully observe the information provided in Chapter "Safety
instructions (Page 15)".
WARNING
Burns caused by inadequate cable insulation
Improperly laid or damaged cables and incorrectly attached cable shieldings can heat up in
places and cause fires or short-circuits wherever they make contact.
● Check whether all the cable shields are intact.
● Insulate damaged cable shields.
● Make sure that a short-circuit cannot occur on the power cables due to failure of the
insulation as a result of incorrect cable installation.
NOTICE
Damage if the auxiliary power supply is not available
When the auxiliary power supply is switched off, data about error message statuses can be
lost. Inadequate diagnostic and error rectification measures can result in material damage.
● We recommend using an uninterruptible power supply (UPS). If you are unsure of the
measures necessary after the device fails, or if a fault cannot be rectified, contact the
Service Center.
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 81)".
NOTICE
Damage caused by an incomplete repair
In the case of damage, several components can have a fault condition. Consequential
damage can occur if the device is recommissioned but the repair work carried out was not
complete.
● Check whether secondary faults have occurred on components which have failed.
Replace the components involved.
WARNING
Danger to life when replacing components that are not permitted to be replaced
Incorrect replacement of components can result in death, severe injury and material damage.
● Replace only those components that are allowed to be replaced.
● Contact the Service Center if other components are defective. You can find the relevant
contact persons at "Service & Support (Page 133)".
9.7.2 Torques
The following table contains the default values. If the replacement of a component requires
different torques, they are specified in the associated sections.
Screw type Soft materials S31 Hard materials S22 Hard materials S13
nm in - lb nm in - lb nm in - lb
M3 0.8 7.1 1.8 15.9 1.3 11.5
M4 1.8 15.9 3.9 34.5 3.0 26.6
M5 3.0 26.6 7.8 69.0 6.0 53.1
M6 6.0 53.1 13.0 115 10.0 88.5
M8 13.0 115 32.0 283 25.0 221
M10 25.0 221 65.0 575 50.0 443
Screw type Soft materials S31 Hard materials S22 Hard materials S13
nm in - lb nm in - lb nm in - lb
M12 50.0 443 115.0 1020 88.0 779
M16 115.0 1020 270.0 2390 215.0 1900
1
Examples of soft materials are Cu, Al, CuZn cable entries, laminate materials, plastics, cast
resin post insulators, press nuts, welding nuts, blind rivet nuts, and cage nuts.
2
Hard materials S2 are materials with friction-enhancing washer components, e.g. a contact
washer.
3
Hard S1 materials include steel, for example.
Table 9-4 Tightening torques for screw terminals for copper cables without cable lug 1)
Screw type Set screws and Head screws with Head screws with
headless screws slit hexagon profile
nm in - lb nm in - lb nm in - lb
M2 - - -
M2.5 0.25 2.2 0.5 4.4 0.5 4.4
M3 0.3 2.7 0.6 5.3 0.6 5.3
M3.5 0.5 4.4 1.0 8.9 1.0 8.9
M4 0.8 7.1 1.3 11.5 1.3 11.5
M5 1.0 8.6 2.5 22.1 2.5 22.1
M6 1.3 11.5 3.0 26.6 3.5 31.0
M8 1.8 15.9 3.9 34.5 7.2 63.7
M10 - - 4.8 42.5 13 115
M12 - - - - 18 159.3
M16 - - - - 30 265.5
Observe the tightening torques of the terminal manufacturer and the test torques according to
DIN EN 60999-1, VDE 609-1
The AVT combination modules are part of the actual value acquisition module. The installation
location is described in the layout diagram.
WARNING
High voltages
The AVT combination modules and measuring resistors are at hazardous voltage levels.
Touching actual value acquisition components, particularly measuring resistors or LEM
current transformers, can result in death, serious injury, or material damage.
● Do not touch AVT combination modules, LEM current transformers, or measuring resistors
under any circumstances.
● Do not make any changes to the design of the actual value acquisition.
WARNING
Danger to life as a result of incorrect replacing the precharging transformer
Replacing the precharging transformer incorrectly can result in death, serious injury, or
material damage.
● Follow "the five safety rules (Page 15)".
● Before replacing the precharging transformer, open the safety disconnector for the 400 V
supply.
● Lift the transformer carefully because it is heavy (> 45 kg).
Removing modules
To remove a pre-charging rectifier module, proceed as follows:
1. Loosen the five plastic screws ① on the cover.
Installing a module
Install the new module in the reverse order to when you removed it.
WARNING
Danger to life as a result of defective discharge resistors
High voltages may occur at the DC link capacitors of the power cells due to defective
discharge resistors. Touching live components can result in death or serious injury.
● The five safety rules (Page 15) must be observed.
● Before replacing a power cell, ensure the following:
– The power cell is grounded at the input and output.
– There is no voltage at the power cells.
Check that the power cells are in a no-voltage condition at the terminals of the power
cell as well as the connections of the capacitor bank.
CAUTION
Risk of injury caused by incorrectly removing a power cell
Each power cell comprises two mechanical units, which can be separated:
● IGBT module weighing about 12 kg
● The capacitor bank with a weight of approx. 44 kg
Removing the power cells incorrectly can lead to serious injury and material damage.
● When installing and removing the power cell, do not position yourself below the individual
units.
NOTICE
Malfunction when replacing individual capacitors
It is not permissible to individually replace capacitors in the capacitor bank. If this is not
observed, this can result in malfunction.
● Only replace the complete capacitor bank.
NOTICE
Damage to components when using impact screwdrivers
Even with the correct torque, components can be damaged when using an impact
screwdriver. This can cause the device to fail.
● Never use an impact screwdriver.
Required 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
8. Remove the two screws (M5 x 25) ⑦ between the heat sink and the housing of the capacitor
bank.
9. Remove all screws (M8 x 20) ⑧ between the capacitor busbar and the gating unit.
10.Remove the gating unit by withdrawing it to the front.
11.Remove the screws ⑨ (M4 x 10). Withdraw the plate towards the front.
12.Loosen the bolted connection ⑩ (M8 x 30). Remove the screw ⑪ (M8 x 16) of the capacitor
bank.
In the example, five capacitors each with a value of 1.2 mF are installed. The value in this
example must have at least 6 mF up to max 6.3 mF with a tolerance of max. + 5 %. Any
deviation of the measured capacitance signifies one or several defective capacitors. In this
case, replace the capacitor bank.
NOTICE
Malfunction when replacing individual capacitors
It is not permissible to individually replace capacitors in the capacitor bank. If this is not
observed, this can result in malfunction.
● Only replace the complete capacitor bank.
Final checks
1. Make sure that all the screws have been tightened with the correct torques.
NOTICE
Damage and/or short-circuits at the double submodules caused by an incorrect tightening
torque
If you do not comply with the screw tightening torques, then this can lead to damage and/
or short-circuits at the power cells.
● When installing the power cells comply with the specified torques.
2. Check whether all of the couplings of the cooling water connections are correctly inserted
and interlocked (shift the plastic ring towards the front and insert the locking ring).
NOTICE
Damage to the gating unit if the locking ring is not inserted
The gating unit can be damaged if the flow of water through the heatsink is not guaranteed.
In order to guarantee a reliable flow of water through the heat sink, the locking ring must
be correctly inserted.
● After the water coupling has been interlocked, insert the locking ring into the slot
between the locking ring and the coupling.
● If the locking ring cannot be inserted, then check whether the water coupling is correctly
inserted and interlocked.
Note
Ventilating the deionized water circuit
Vent the deionized water circuit after replacing a power cell.
WARNING
Danger to life due to electric shock at the snubber circuit capacitors
The snubber circuit capacitors are not always equipped with discharge resistors. The energy
stored in the capacitors is discharged via a diode. Voltages of up to several 1000 V can occur
and cause an electric shock. This can result in death, severe injuries and significant material
damage.
● You should always handle the capacitors as if they are charged.
● Discharge the snubber circuit capacitors. Short-circuit the snubber circuit capacitors briefly
before you withdraw the diode stack.
Tool required
● Socket wrench set
● Set of open-ended wrenches
● Torque wrench up to 50 Nm
● Ratchet with short extension
● Ratchet length extension
● Side cutters
● Short slotted screwdriver, Size 2
● Screwdriver, Torx T30
● Cable ties
● Touch-up pen, e.g., Edding 751.
9.7.8.2 Removing
Preparations
1. Close the water intakes and outlets of the diode stack to be removed.
2. Remove the doors To do this, remove the screws ① of the door hinges on the bar.
3. Remove the cable ties ③ that fix the water hoses. Remove the front and rear spacers ④ of
the water hoses at the diode stack. Unscrew the spacers in an anti-clockwise direction.
CAUTION
Leakage as a result of a defective coupling
If you unscrew the coupling with the inserted hose from the diode stack, then the hose can
be damaged as a result of the coupling teeth. This can result in leaks.
● To release the water inlets and outlets, only withdraw the hose from the coupling.
CAUTION
Eye and skin injuries caused by deionized water
Deionized water is harmful to eyes and skin and can damage surfaces.
● Therefore, use appropriate protective clothing when you carry out any work on the
drive. However, if your eyes or skin do come into contact with deionized water, rinse the
affected area thoroughly with tap water as soon as possible.
● If deionized water leaks out, eliminate the source of the problem and remove the liquid
from the surfaces affected.
3. Remove all of the cable ties ④ that fix the cables of the capacitor module. Withdraw the
connections at the bottom ⑤ and top ⑥ from the modules.
2. Withdraw the diode stack out of the cabinet towards the front.
CAUTION
Risk of injury as a result of incorrectly handling the diode stack
The diode stack is very heavy (approx. 30 kg). When incorrectly handled, the diode stack
can cause injury and material damage.
● Take special care when lifting the diode stack out of the drive.
9.7.8.3 Installing
● Perform the installation in the reverse order to the steps described for the removal.
● Comply with the specified torques. The torques are listed in Section "Repairing".
● Also observe the notes in the following section.
CAUTION
Wire jumper between the connections of the capacitor module
A wire jumper is located between the connections ① of the capacitor module. If the wire
jumper is not removed, this results in a short-circuit.
This may result in damage to property or physical injury.
Remove the wire jumper prior to installation.
Diode stack
Note
Mounted parts and components
Remove mounted components, e.g. brackets, which are not provided at/on the new diode stack
from the diode stack that you just removed. Mount these parts and components onto the new
diode stack.
● When installing the diode stack, always use new screws, washers and nuts.
● Insert the water hoses into the couplings up to the marking.
● Fix the capacitor cables using cable ties.
● Fasten the water hoses to the spacers using cable ties.
● Open the water intakes and outlets.
● Ventilate the deionized water circuit.
Mounting doors
1. To orientate the right hinge position, use the impression of the hinge in pen on the bar. If
despite this, adjustment to the doors is required, loosen the nuts ① of the corresponding
close pin bracket. Adjust the close pin bracket. Retighten the nuts.
NOTICE
Device damage due to water
If water enters the cabinet while a water sensor is being replaced, this can result in material
damage.
● Before replacing a water sensor, empty the entire water circuit and blow out the piping.
● Before screwing into the adapter element, seal the outer thread using LOCTITE 586-
AVX(ROHRD)RT sealant. The Siemens order number for the sealant is 534032.
Removing a sensor
To remove a sensor, proceed as follows:
1. Loosen the screw in the sensor cover ①.
2. Pull out the connector.
3. For the temperature sensor, loosen the two screws in the sensor cover ②.
4. Remove the cables connected to the sensor.
5. Unscrew the sensor from the screw connection in the water pipe.
Installing a sensor
To install a sensor, proceed as follows:
1. Screw the sensor into the screw connection in the water pipe.
2. Attach the connector to the sensor.
3. Fasten the screws in the sensor cover ①.
4. For the temperature sensor, attach the cables directly to the sensor.
5. Lock the sensor by using the two screws ② to screw the cover to the sensor.
Note
Ventilating the deionized water circuit
Vent the deionized water circuit after replacing a water sensor.
8. Insert the SD card into the system slot ① of the operator panel.
① System slot
② Data slot
Figure 9-25 Card slots
9. Start the operator panel by switching on the power supply. The software is installed.
10.Confirm that you want the existing HMI project to be overwritten.
11.After completing the software installation, insert the SD card in the data slot ② of the
operator panel.
NOTICE
Destruction of the CompactFlash card
The CompactFlash card must only be inserted or removed when the power is off.
Otherwise there is a risk of data loss or damage to the card, which would prevent
commissioning of the drive.
● Only remove or insert the CompactFlash card when the power is switched off.
2. Withdraw the CompactFlash card from the Control Unit. Back up the data saved on it.
3. Copy the stored data of the previous CompactFlash card to the new original Siemens card.
Note
Invalid software key
The software key is associated with the serial number of the CompactFlash card. If you
overwrite the software key of the new CompactFlash card with the previous CompactFlash
card, the new CompactFlash card is not operational.
Consequently, use the software key of the new CompactFlash card.
Always indicate the part number and - if known - the order number of the spare part required.
You can find the order number as follows:
● The device label is attached to or next to each component. Find out which item code the
required spare part has. The parts list provided specify the part number and, where
appropriate, the article number corresponding to the equipment identifier.
● For inquiries by email, send a photo of the product, spare part and nameplate if possible.
Use Spares on Web (https://www.sow.siemens.com/) to obtain ordering information about
spare parts.
A list of parts and components can be found in the separate document "Technical data and
drawings".
WARNING
Danger caused by improper removal
In the event of improper removal, material can slip, tilt or fall down. This can result in death,
serious injury or material damage.
● Only specialist personnel may disassemble and dispose of device components and old
devices using appropriate protective clothing.
● Shut down the device before disassembling.
● Ground the device
● For old equipment, observe the information in the "Transport" chapter.
For the following components, pay special attention when disposing or reusing:
● Batteries
● Capacitors
● PCBs
● Electronic components
Note
Finding technical data and drawings
You will find plant-specific information in the separate document "Technical data and drawings."
Storage with suitable packag‐ Transport with suitable pack‐ Operation (industrial)
ing aging
Ambient temperature -25° C to +70° C -25° C to +70° C 5° C to +40° C
Relative humidity 5% to 95% 5 % to 95 % 5% to 85%
(Only low condensation is (Only slight condensation is (Condensation is not permit‐
permitted. The device must permissible. The device must ted)
be completely dry before be completely dry before
commissioning.) commissioning.)
Other climatic conditions ac‐ 1K22 according to DIN EN 2K11 according to DIN EN 3K3 according to DIN EN
cording to class 60721‑3‑1 (IEC 60721‑3‑1) 60721‑3‑2 (IEC 60721‑3‑2) 60721‑3‑3/A2:1997
Icing not permissible (IEC 60721‑3‑3/Ed2.2:2008)
Pollution degree 2 without conductive pollution 2 without conductive pollution 2 without conductive pollution
according to DIN EN 50178 / according to DIN EN 50178 / according to DIN EN 50178 /
VDE 0160 VDE 0160 VDE 0160
(IEC 62103) (IEC 62103) (IEC 62103)
Note
Quality documents
You can find all quality verifications relating to the device, such as declarations on the
conformity of the device with directives or specifications in the "Quality documents" in a
separate part of this manual.
V
R
Voltage-source DC link drive., 31
REACH regulation, 131