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Power Modul
es
4.2
Block
size Pow
er Modu
les (PM2
40
-
2)
AC Driv
e
92
Manual
,
(GH6), 04/2014
,
6S
L3097
-
4AL00
-
0BP4
Figure
4-2
PM240
-
2, fram
e size FS
B (vi
ew fr
om below
and front)
Figure
4-3
PM240
-
2, fram
e size FS
B (vi
ew fr
om below
and front)
91
93
Table of Contents
Main Page
Default Chapter
5
Foreword
5
Table of Contents
11
1 Fundamental Safety Instructions
21
General Safety Instructions
21
Safety Instructions for Electromagnetic Fields (EMF)
24
Handling Electrostatic Sensitive Devices (ESD)
25
Industrial Security
25
Residual Risks of Power Drive Systems
26
2 System Overview
29
Field of Application
29
Platform Concept and Totally Integrated Automation
31
Overview, SINAMICS S120 AC Drive
32
SINAMICS S120 Components
33
System Data
35
Derating as a Function of the Ambient Temperature, Pulse Frequency, and Installation Altitude
37
3 Mains Connection and Line-Side Power Components
39
Introduction
39
Information on the Disconnector Unit
40
Overcurrent Protection by Means of Line Fuses and Circuit Breakers
41
Using Residual-Current Devices
41
Overvoltage Protection
42
Line Contactors
43
Line Filter
44
Description
44
Classification of EMC Behavior
44
Electromagnetic Compatibility (EMC) of the System
45
Safety Instructions for Line Filters
47
Dimension Drawings
48
Mounting
53
Technical Data
54
Technical Data, Blocksize Line Filter
54
Technical Data, Chassis Line Filter
55
Line Reactors
56
Description
56
Safety Instructions for Line Reactors
56
Dimension Drawings
58
Mounting
64
Electrical Connection
71
Technical Data
72
Blocksize Line Reactors
72
Chassis Line Reactors
75
Line Connection Variants
76
Operation on Different Line System Configurations
76
Methods of Line Connection
79
Operation of the Line Connection Components on the Supply Line
81
Operation of the Line Connection Components Via an Autotransformer
82
Operation of the Line Connection Components Via an Isolating Transformer
83
4 Power Modules
85
Safety Instructions for Power Modules
85
Blocksize Power Modules (PM240-2)
88
Description
88
Safety Information for 240-2 Power Modules
90
Interface Description
91
Overview
91
Connection Example
93
Line Supply Connection
94
Braking Resistor and DC Link Connection
94
Motor Connection
94
Safe Brake Relay Connection
95
Dimension Drawings
95
Mounting
103
Mounting Dimensions and Tightening Torques
104
Mounting the Shielding Plate
105
Technical Data
106
200 V Power Modules
106
400 V Power Modules
111
Characteristics
117
Power Modules Blocksize (PM340)
121
Description
121
Safety Instructions for Power Modules Blocksize Format
123
Interface Description
124
Overview
124
Connection Example
130
Line Supply Connection
132
Braking Resistor and DC Link Connection
132
Motor Connection
133
Safe Brake Relay Connection
133
Dimension Drawings
134
Mounting
142
Mounting Dimensions and Tightening Torques
142
Access to the Power Supply Terminals and Motor Terminals
144
Technical Data
145
Power Modules Blocksize, 1-Ph. AC
145
Power Modules Blocksize, 3-Ph. AC
147
Characteristics
154
Power Modules Chassis
159
Description
159
Safety Instructions for Power Modules Chassis Format
159
Interface Description
160
Overview
160
Connection Example
162
Terminal Block X9
163
DCPS, DCNS Connection for a DV/Dt Filter
163
X41 EP Terminal / Temperature Sensor Connection
164
X42 Terminal Strip
165
X46 Brake Control and Monitoring
166
DRIVE-Cliq Interface X400-X402
166
Meaning of the Leds on the Power Module
167
Dimension Drawings
168
Electrical Connection
170
Technical Data
172
Characteristics
174
600 DC Link Components
179
Blocksize
179
Braking Resistors
179
Description
179
Safety Instructions for Blocksize Braking Resistors
179
Connection Examples
181
Dimension Drawings
182
Installation
186
Technical Data
187
Chassis
192
Braking Modules
192
Description
192
Safety Instructions for Braking Modules Chassis Format
193
Braking Module for Frame Size FX
194
Braking Module for Frame Size GX
195
Connection Example
196
Braking Resistor Connection X1
197
X21 Digital Inputs/Outputs
197
S1 Threshold Switch
198
Installing a Braking Module in a Power Module, Frame Size FX
199
Installing a Braking Module in a Power Module, Frame Size GX
201
Technical Data
203
Braking Resistors
204
Description
204
Safety Instructions for Braking Resistors Chassis Format
204
Dimension Drawing
207
Electrical Connection
208
Technical Data
208
6 Motor-Side Power Components
211
Blocksize
211
Motor Reactors
211
Description
211
Safety Instructions for Motor Reactors
211
Dimension Drawings
213
Mounting
221
Electrical Connection
227
Technical Data
228
Chassis
231
Motor Reactors
231
Description
231
Safety Instructions for Motor Reactors
231
Dimension Drawing
233
Technical Data
234
Sinusoidal Filter
235
Description
235
Safety Instructions for Sine-Wave Filter Chassis Format
235
Dimension Drawing
237
Technical Data
238
DV/Dt Filter Plus Voltage Peak Limiter
239
Description
239
Safety Instructions for Du/Dt Filter Plus Voltage Peak Limiter
239
Interface Description
242
Connecting the DV/Dt Filter Plus Voltage Peak Limiter
243
Dimension Drawing, DV/Dt Reactor
244
Dimension Drawing of the Voltage Peak Limiter
245
Technical Data
246
DV/Dt Filter Compact Plus Voltage Peak Limiter
247
Description
247
Safety Instructions for Du/Dt Filter Compact Plus Voltage Peak Limiter
247
Interface Description
251
Connecting the DV/Dt Filter Compact Plus Voltage Peak Limiter
252
Dimension Drawing of DV/Dt Filter Compact Plus Voltage Peak Limiter
253
Technical Data
255
7 Control Units, Control Unit Adapters and Operating Components
257
Introduction
257
Control Units
257
Control Unit Adapter
259
Safety Instructions for Control Units and Control Unit Adapters
260
Control Unit CU310-2 PN (PROFINET)
262
Description
262
Interface Description
263
Overview
263
X22 Serial Interface (RS232)
264
X23 HTL/TTL/SSI Encoder Interface
265
X100 DRIVE-Cliq Interface
268
X120 Digital Inputs (Fail-Safe)/Ep Terminal/Temperature Sensor
269
X121 Digital Inputs/Outputs
271
X124 Electronics Power Supply
273
X127 LAN (Ethernet)
274
X130 Digital Input (Fail Safe) Digital Output
275
X131 Digital Inputs/Outputs and Analog Input
276
X150 P1/P2 Profinet
278
Measuring Sockets
279
S5 DIP Switch
279
DIAG Button
279
RESET Button
279
Memory Card
280
Connection Examples
281
Meaning of the Leds
283
Function of the Leds
283
Behavior of the Leds During Booting
284
Behavior of the Leds in the Operating State
285
Dimension Drawing
286
Technical Data
287
Control Unit CU310-2 DP (PROFIBUS)
288
Description
288
Interface Description
289
Overview
289
X21 Profibus
290
PROFIBUS Address Switch
291
X22 Serial Interface (RS232)
292
X23 HTL/TTL/SSI Encoder Interface
293
X100 DRIVE-Cliq Interface
296
X120 Digital Inputs (Fail-Safe)/Ep Terminal/Temperature Sensor
297
X121 Digital Inputs/Outputs
299
X124 Electronics Power Supply
301
X127 LAN (Ethernet)
302
X130 Digital Input (Fail Safe) Digital Output
303
X131 Digital Inputs/Outputs and Analog Input
304
Measuring Sockets
306
S5 DIP Switch
306
DIAG Button
306
RESET Button
306
Memory Card
307
Connection Examples
308
Meaning of the Leds
310
Function of the Leds
310
Behavior of the Leds During Booting
311
Behavior of the Leds in the Operating State
312
Dimension Drawing
314
Technical Data
315
Control Unit Adapter CUA31
316
Description
316
Interface Description
317
Overview
317
X200-X202 DRIVE-Cliq Interfaces
318
X210 EP Terminal / Temperature Sensor
319
X224 Electronics Power Supply
320
Connection Example
320
Meaning of the Leds
321
Dimension Drawing
321
Technical Data
322
Control Unit Adapter CUA32
323
Description
323
Interface Description
324
Overview
324
X200-X202 DRIVE-Cliq Interfaces
325
X210 EP Terminal / Temperature Sensor
326
X220 HTL/TTL/SSI Encoder Interface
327
X224 Electronics Power Supply
329
Connection Example
329
Meaning of the Leds
330
Dimension Drawing
331
Technical Data
331
Mounting Control Units and Control Unit Adapters
332
Basic Operator Panel BOP20
334
Description
334
Interface Description
334
Mounting
337
8 Supplementary System Components and Encoder System Integration
341
Sensor Modules
341
Safety Instructions for Sensor Modules Cabinet-Mounted
341
Sensor Module Cabinet-Mounted SMC10
343
Description
343
Interface Description
343
Meaning of the Leds
347
Dimension Drawing
348
Mounting
349
Technical Data
350
Sensor Module Cabinet-Mounted SMC20
352
Description
352
Interface Description
352
Meaning of the Leds
356
Dimension Drawing
357
Mounting
358
Technical Data
359
Sensor Module Cabinet-Mounted SMC30
360
Description
360
Interface Description
360
Connection Examples
367
Meaning of the Leds
369
Dimension Drawing
370
Mounting
371
Protective Conductor Connection and Shield Support
372
Technical Data
373
Option Module Safe Brake Relay
378
Introduction
378
Safety Instructions for Safe Brake Relays
378
Interface Description
379
Overview
379
X524 Electronics Power Supply
379
Brake Connection
380
Connection Example
380
Dimension Drawing
381
Mounting
382
Technical Data
383
Safe Brake Adapter Optional Module
384
Description
384
Safety Instructions for Safe Brake Adapters
385
Interface Description
386
Overview
386
X11 Interface to the Control Interface Module
387
X12 230 V AC Power Supply
387
X14 Load Connection
388
X15 Fast De-Energization
388
Connection Example
389
Dimension Drawing
389
Mounting
390
Technical Data
390
9 Accessories
391
DRIVE-Cliq Cabinet Bushing
391
Description
391
Interface Description
392
Overview
392
Dimension Drawings
393
Installation
394
DRIVE-Cliq Cabinet Bushing for Cables with DRIVE-Cliq Connectors
394
DRIVE-Cliq Cabinet Bushing for Cables with M12 Plug/Socket
396
Technical Data
397
DRIVE-Cliq Coupling
398
Description
398
Interface Description
398
Overview
398
Dimension Drawing
399
Mounting
399
Technical Data
400
Mounting Frame
401
Description
401
Dimension Drawings
402
Mounting
403
Shield Connection Kit
404
Description
404
Dimension Drawings
405
Shield Connection Kits
405
Blocksize Power Modules with Shield Connection Kit
407
Mounting
412
PM340 Blocksize Power Modules
412
Power Cable Connection
415
10 Cabinet Design and EMC for Components, Blocksize Format
417
General Information
417
Safety Instructions for Control Panel Manufacturing
418
Notes on Electromagnetic Compatibility (EMC)
419
Cable Shielding and Routing
420
DC Supply Voltage
422
General
422
Overcurrent Protection
423
Overvoltage Protection
424
Typical 24 V Current Consumption of the Components
425
Selecting Power Supply Units
426
Connection Methods
427
DRIVE-Cliq Signal Cables
427
Overview
427
DRIVE-Cliq Signal Cables Without 24 V DC Cores
428
DRIVE-Cliq Signal Cables MOTION-CONNECT with DRIVE-Cliq Connectors
429
MOTION-CONNECT DRIVE-Cliq Signal Cables with DRIVE-Cliq Connector and M12
429
Socket
429
Comparison of DRIVE-Cliq Signal Cables
431
Combined Use of MOTION-CONNECT 500 and MOTION-CONNECT 800PLUS
432
Power Cables for Motors
433
Configuring the Cable Length
433
Comparison of MOTION-CONNECT Power Cables
434
Current-Carrying Capacity and Derating Factors for Power Cables and Signal Cables
435
Spring-Loaded Terminals
437
Screw Terminals
437
Protective Connection and Equipotential Bonding
438
Arrangement of Components and Equipment
440
General
440
Mounting
441
Information on Control Cabinet Cooling
443
General
443
Ventilation
445
Power Loss of Components in Rated Operation
447
General
447
Power Loss of Control Units, Control Unit Adapters and Sensor Modules
447
Power Loss for Line Reactors and Line Filters
448
Power Loss for Power Modules
450
11 Service and Maintenance
453
Safety Instructions for Service and Maintenance
453
Service and Maintenance for Components, Blocksize Format
454
Replacing Hardware Components
454
Replacing the Fan CU310-2 DP and CU310-2 PN
454
Replacing the Fan on the PM240-2
456
Replacing the Fan on the PM340
457
Service and Maintenance for Chassis Format Components
463
Maintenance
463
Installation Equipment
465
Replacing Components
466
Replacing the Powerblock, Power Module, Frame Size FX
466
Replacing the Powerblock, Power Module, Frame Size GX
469
Replacing the Control Interface Module, Power Module, Frame Size FX
472
Replacing the Control Interface Module, Power Module, Frame Size GX
474
Replacing the Fan, Power Module, Frame Size FX
476
Replacing the Fan, Power Module, Frame Size GX
478
Forming the DC Link Capacitors
480
Spare Parts
484
Recycling and Disposal
484
Appendix
485
List of Abbreviations
485
Documentation Overview
494
A.2 Documentation Overview
494
Index
495
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