Operating Instructions Installation Instructions Medium-Voltage Drive SINAMICS GM150 Type 6SL3835-2LN44-2AA0 Edition 04/2017 www.siemens.com/drives 20.04.2017 13:31 V27.00 Introduction 1 Safety instructions 2 Medium-Voltage Drive Description 3 SINAMICS GM150 Type 6SL3835-2LN44-2AA0 Preparations for use 4 Installation 5 Electrical connection 6 Start-up 7 Operation 8 Maintenance 9 Spare parts 10 Disposal 11 Operating Instructions Installation Instructions Edition 04/2017 Service & Support A Technical data and drawings B Checklists and forms C 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 (R) are registered trademarks of Siemens AG. The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner. Disclaimer of Liability We have reviewed the contents of this publication to ensure consistency with the hardware and software described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in this publication is reviewed regularly and any necessary corrections are included in subsequent editions. Siemens AG Process Industries and Drives Postfach 48 48 90026 NURNBERG GERMANY Document order number: MUSTER_Diodestack 04/2017 Subject to change Copyright (c) Siemens AG 2006, -, 2017. All rights reserved Table of contents 1 Introduction.................................................................................................................................................17 1.1 2 3 About these instructions.........................................................................................................17 Safety instructions......................................................................................................................................19 2.1 Warning symbol on the device...............................................................................................19 2.2 Qualified personnel................................................................................................................19 2.3 The five safety rules...............................................................................................................19 2.4 Safe handling.........................................................................................................................20 2.5 Electromagnetic fields in electrical power engineering installations ......................................23 2.6 Components that can be destroyed by electrostatic discharge (ESD)...................................24 2.7 2.7.1 2.7.2 2.7.3 2.7.4 2.7.5 Information for nominated persons in control of an electrical installation...............................25 Proper usage..........................................................................................................................25 Security information...............................................................................................................26 Grounding concept.................................................................................................................27 Installation site safety.............................................................................................................27 Measures for operator protection in electromagnetic fields...................................................28 2.8 Residual risks.........................................................................................................................28 Description..................................................................................................................................................31 3.1 Applications............................................................................................................................31 3.2 3.2.1 3.2.2 3.2.3 3.2.4 Safety concept.......................................................................................................................31 Safety components and functions..........................................................................................31 External safety components...................................................................................................32 Protection and monitoring functions of internal components.................................................32 Protection and monitoring functions for external components...............................................33 3.3 3.3.1 3.3.2 3.3.3 3.3.4 Design....................................................................................................................................33 Components...........................................................................................................................33 Design of the Basic Line Module............................................................................................34 Design of the Motor Module...................................................................................................35 Gating.....................................................................................................................................36 3.4 Operating principle.................................................................................................................36 3.5 3.5.1 3.5.2 3.5.3 3.5.4 3.5.5 3.5.6 3.5.7 3.5.8 Description of the components...............................................................................................37 SINAMICS Control Unit..........................................................................................................37 Terminal Modules...................................................................................................................37 Precharging............................................................................................................................37 Electromechanical door interlock system...............................................................................38 Make-proof grounding switch.................................................................................................38 Circuit-breaker (provided by the customer)............................................................................38 Converter transformer............................................................................................................39 Power Stack Adapter.............................................................................................................40 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 5 Table of contents 3.5.9 3.5.10 3.5.10.1 3.5.10.2 3.5.10.3 3.5.10.4 3.5.11 3.5.11.1 3.5.11.2 3.5.11.3 3.5.11.4 3.5.11.5 3.5.12 3.5.12.1 3.5.12.2 3.5.12.3 3.5.13 Actual value acquisition..........................................................................................................42 Common power supply..........................................................................................................42 Field of application.................................................................................................................42 Design....................................................................................................................................43 Connections...........................................................................................................................44 Interface description...............................................................................................................44 DM10 diagnostics module......................................................................................................45 Functions................................................................................................................................45 Measuring socket assignment................................................................................................47 Interface description of the connectors..................................................................................47 Signal processing...................................................................................................................51 Voltage monitoring.................................................................................................................52 Re-cooling unit ......................................................................................................................53 Re-cooling unit requirements.................................................................................................53 Operating principle of the re-cooling unit...............................................................................53 The internal deionized water circuit........................................................................................54 Customer terminal strips........................................................................................................54 3.6 3.6.1 3.6.2 3.6.3 3.6.4 3.6.5 3.6.6 3.6.7 3.6.8 3.6.9 3.6.10 3.6.11 3.6.12 3.6.13 Description of options.............................................................................................................55 NAMUR terminal strip (option B00)........................................................................................55 Auxiliary voltage supply 3 AC 200 V 50 Hz (option C30).......................................................55 Suitable for marine use with individual certificate from Lloyds Register (LR) (option E21)......56 Isolation amplifiers for optional analog inputs (option E86)....................................................56 Isolation amplifiers for optional analog outputs (option E87).................................................56 Can Bus interface (option G20)..............................................................................................57 Modbus RTU Slave interface (option G22)............................................................................57 1x temperature sensor evaluation unit TM150 (option G51)..................................................57 Additional Terminal Module TM31 (option G61)....................................................................57 Additional Terminal Module TM15 (option G63)....................................................................58 PADU8 diagnosis module (option G66).................................................................................58 Indicator lamps in the cabinet door (option K20)....................................................................59 Display instruments in the cabinet door for voltage, current, speed, and output plus indicator lamps (option K21)..................................................................................................59 Sensor Module SMC30 (option K50).....................................................................................59 dv/dt filter (option L10)...........................................................................................................60 dv/dt filter (option L11)...........................................................................................................62 Automatic restart function (option L32)..................................................................................63 Line-side grounding switch (option L48)................................................................................64 Motor-side grounding switch (option L49)..............................................................................64 Cabinet illumination and service socket in closed-loop control unit (option L50)...................65 Disconnector at the drive output (option L51)........................................................................65 Circuit breaker at the drive output (option L52)......................................................................65 Uninterruptible power supply (UPS) (option L53)...................................................................65 Anti-condensation heating (option L55).................................................................................66 EMERGENCY STOP Category 1 (option L60)......................................................................66 Braking Module (option L72)..................................................................................................67 Safety locking system (option M10).......................................................................................67 Power cable connection at the drive input from above (option M13).....................................67 Signal and control cable (max. 2.5 mm) (option M32)..........................................................68 IP54 degree of protection (option M54)..................................................................................68 Redundant fan in the power unit (option M61).......................................................................68 Suitability for marine use (option M66)...................................................................................68 Controlled outgoing circuit for auxiliary equipment 400 V 3 AC (option N30).......................69 3.6.14 3.6.15 3.6.16 3.6.17 3.6.18 3.6.19 3.6.20 3.6.21 3.6.22 3.6.23 3.6.24 3.6.25 3.6.26 3.6.27 3.6.28 3.6.29 3.6.30 3.6.31 3.6.32 3.6.33 6 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Table of contents 3.6.34 4 5 6 Sine-wave filter (option Y15)..................................................................................................69 Preparations for use...................................................................................................................................71 4.1 Requirements for installation location....................................................................................71 4.2 4.2.1 4.2.2 4.2.3 4.2.4 Inspections when receiving the delivery.................................................................................71 Checking the delivery.............................................................................................................71 Scope of delivery....................................................................................................................72 Checking shock and tilt indicators..........................................................................................72 Checking the load handling attachments...............................................................................73 4.3 4.3.1 4.3.2 4.3.3 4.3.4 4.3.5 4.3.6 4.3.7 Transportation........................................................................................................................74 Transport markings................................................................................................................74 Transport requirements..........................................................................................................74 Observe center of gravity.......................................................................................................75 Transport with a fork-lift truck.................................................................................................75 Transport with a crane...........................................................................................................76 Using lifting rods.....................................................................................................................76 Transporting transportation units packed in boxes................................................................78 4.4 4.4.1 4.4.2 4.4.3 4.4.4 4.4.4.1 4.4.5 Unpacking..............................................................................................................................79 Removing the packaging........................................................................................................79 Removing load securing devices...........................................................................................80 Lifting the cabinet off the transport pallet...............................................................................80 Opening doors in preparation for use.....................................................................................81 Opening doors in preparation for use.....................................................................................81 Checking the shock and tilt indicators inside the cabinet.......................................................82 4.5 4.5.1 4.5.2 Storage...................................................................................................................................82 Emptying the drive.................................................................................................................82 Storing a device.....................................................................................................................83 Installation..................................................................................................................................................85 5.1 Safety instructions for assembly............................................................................................85 5.2 Tools required........................................................................................................................86 5.3 Attaching side panels.............................................................................................................86 5.4 Screwing the transport units together....................................................................................87 5.5 Connecting to the foundation.................................................................................................88 5.6 Connecting cabinets...............................................................................................................89 5.7 Connecting the DC bus..........................................................................................................90 5.8 Connecting the interface terminals.........................................................................................91 5.9 Connecting the water circuits.................................................................................................92 5.10 Installing the battery of the uninterruptible power supply.......................................................93 Electrical connection...................................................................................................................................95 6.1 Safety instructions for electrical connections.........................................................................95 6.2 Electromagnetic compatibility.................................................................................................97 6.3 Potential concept..................................................................................................................100 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 7 Table of contents 7 6.4 Electrical requirements.........................................................................................................100 6.5 6.5.1 6.5.2 6.5.3 6.5.4 6.5.5 6.5.6 6.5.7 6.5.8 6.5.9 6.5.10 Connection...........................................................................................................................101 Manually unlocking power-unit doors...................................................................................101 Preparations for connecting the power cables.....................................................................101 Connecting power cables.....................................................................................................101 Connect the power cable to the motor and the supply system............................................102 Connecting ground...............................................................................................................104 Connect the auxiliary voltage...............................................................................................105 Connecting the encoder to the SMC30 Sensor Module.......................................................106 Interconnecting optional connections...................................................................................108 Connecting the re-cooling unit to the drive...........................................................................108 Fastening the cable ducts with cable ties.............................................................................108 Start-up ....................................................................................................................................................109 7.1 7.1.1 7.1.2 7.1.3 7.1.4 7.1.5 8 8 Description and configuration of the PROFIBUS interface..................................................109 Hardware components required for PROFIBUS communication ........................................109 PROFIBUS interface, diagnostics LEDs, address switches.................................................110 Connecting PROFIBUS cables............................................................................................112 Setting the PROFIBUS address switches............................................................................113 Requirements for communication via PROFIBUS...............................................................114 Operation..................................................................................................................................................115 8.1 Safety instructions for operation...........................................................................................115 8.2 8.2.1 8.2.1.1 8.2.1.2 8.2.1.3 8.2.2 8.2.2.1 8.2.2.2 8.2.2.3 8.2.3 8.2.3.1 8.2.3.2 8.2.3.3 8.2.3.4 8.2.3.5 8.2.3.6 8.2.3.7 8.2.3.8 Operation via the AOP30 operator panel.............................................................................116 General information about the AOP30 operator panel.........................................................116 AOP30 operator panel.........................................................................................................116 Buttons of the AOP30..........................................................................................................118 Basic operation of the AOP 30.............................................................................................118 Configuration of the AOP30 operator panel.........................................................................121 Define operation screen.......................................................................................................121 Control settings....................................................................................................................125 Inhibit functions....................................................................................................................128 Menu description and setting options...................................................................................131 Operation screen..................................................................................................................131 Parameterization..................................................................................................................133 Fault/alarm memory.............................................................................................................136 Commissioning / service device commissioning..................................................................138 Commissioning / service drive commissioning.....................................................................142 Commissioning / Service - AOP settings.............................................................................143 Commissioning / Service - AOP diagnostics........................................................................147 Language.............................................................................................................................151 8.3 8.3.1 8.3.2 Parameter............................................................................................................................151 Parameters...........................................................................................................................151 Parameter types...................................................................................................................152 8.4 8.4.1 8.4.1.1 8.4.1.2 8.4.1.3 8.4.2 Functions..............................................................................................................................153 Setpoint channel and closed-loop control............................................................................153 Setpoint channel..................................................................................................................153 Vector control.......................................................................................................................156 U/f control.............................................................................................................................159 Analog and digital inputs/outputs.........................................................................................160 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Table of contents 9 8.4.2.1 8.4.2.2 8.4.2.3 8.4.2.4 8.4.2.5 8.4.3 8.4.3.1 8.4.3.2 8.4.3.3 8.4.3.4 8.4.3.5 8.4.3.6 Analog outputs.....................................................................................................................160 Digital outputs......................................................................................................................163 Digital inputs/outputs............................................................................................................164 Additional settings for analog outputs..................................................................................165 Scaling the input signal of the analog inputs........................................................................168 Monitoring functions and protective functions......................................................................169 Insulation monitoring............................................................................................................169 Tripping of the circuit-breaker in case of undervoltage........................................................170 DC-link short-circuiter...........................................................................................................170 Vdc-max closed-loop control................................................................................................171 Speed monitoring with incremental encoder........................................................................173 Controlled stop, EMERGENCY STOP category 1...............................................................173 8.5 8.5.1 8.5.2 8.5.3 8.5.3.1 8.5.3.2 8.5.3.3 Fault and system messages................................................................................................174 External alarms and faults....................................................................................................174 Message from the grounding switch....................................................................................174 Diagnosis.............................................................................................................................175 Indicating and rectifying faults..............................................................................................175 Diagnostics via LEDs...........................................................................................................176 Diagnostics via parameters..................................................................................................177 Maintenance.............................................................................................................................................183 9.1 9.1.1 Safety instructions for maintenance.....................................................................................183 High snubber circuit capacitor voltages...............................................................................183 9.2 9.2.1 9.2.2 Grounding the system..........................................................................................................186 Grounding with a grounding device......................................................................................186 Grounding using a make-proof grounding switch.................................................................188 9.3 9.3.1 9.3.2 9.3.3 Opening the doors................................................................................................................189 Opening the power unit doors for maintenance work...........................................................189 Manually unlocking power unit doors...................................................................................190 Secure locking system (option M10)....................................................................................191 9.4 9.4.1 9.4.2 9.4.3 9.4.3.1 9.4.3.2 9.4.3.3 9.4.3.4 9.4.3.5 Preventive maintenance.......................................................................................................192 Inspection.............................................................................................................................192 Checklist for preventive maintenance work..........................................................................192 Visual inspections................................................................................................................193 Equipment for visual inspections..........................................................................................193 Checking the isolating clearances........................................................................................194 Checking hoisting solenoids and security bolts....................................................................194 Checking the plug connections............................................................................................194 Checking the cable and screw terminals..............................................................................194 9.5 9.5.1 9.5.2 9.5.2.1 9.5.2.2 9.5.3 9.5.4 Maintenance.........................................................................................................................194 Fan maintenance.................................................................................................................194 Filter mats............................................................................................................................195 Replacing filter mats.............................................................................................................195 Replacing the filter mats in the roof assembly.....................................................................196 Replacing the back-up battery of the AOP30 operator panel ..............................................197 Load operator panel firmware, parameter and signal descriptions......................................198 9.6 9.6.1 9.6.2 Cleaning...............................................................................................................................199 Removing dust deposits.......................................................................................................199 Cleaning aluminum parts.....................................................................................................200 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 9 Table of contents 9.7 9.7.1 9.7.2 9.7.3 9.7.4 9.7.5 9.7.6 9.7.7 9.7.8 9.7.9 9.7.10 9.7.11 9.7.12 Repairs.................................................................................................................................200 Torques................................................................................................................................201 Attaching the changing device to the stacker.......................................................................203 Replacing the phase module................................................................................................204 Replacing the diode module.................................................................................................211 Replacing the operator panel...............................................................................................215 Replacing the CompactFlash card.......................................................................................216 Replacing the precharging transformer................................................................................216 Replacing the precharging rectifier......................................................................................218 Replacing the AVT combination module..............................................................................219 Replacing fuses....................................................................................................................219 Replace the sponge for the leak detector............................................................................220 Replacing the Power Stack Adapter....................................................................................221 10 Spare parts...............................................................................................................................................225 11 Disposal....................................................................................................................................................227 11.1 Disposing of packaging material..........................................................................................227 11.2 Removing device components and old devices...................................................................227 A Service & Support.....................................................................................................................................229 B Technical data and drawings....................................................................................................................231 B.1 B.1.1 B.1.2 B.1.3 B.1.4 C B.1.5 B.1.6 B.1.7 Technical specifications.......................................................................................................231 Notes about technical specifications....................................................................................231 Standards and regulations...................................................................................................231 Series connection variant of Basic Line Modules (option N15)............................................232 Connection variant: Performance enhancement through parallel operation of three drive units......................................................................................................................................232 General technical specifications of the drive........................................................................233 Technical specifications of the common power supply........................................................235 Technical specifications of the diagnostics module DM10...................................................235 B.2 B.2.1 B.2.2 B.2.3 B.2.4 B.2.4.1 B.2.4.2 B.2.4.3 B.2.4.4 B.2.4.5 B.2.4.6 B.2.4.7 B.2.4.8 B.2.4.9 Terminal assignments..........................................................................................................236 Control pulpit interface (Terminal Modules TM31 and TM15)..............................................236 Terminal assignment of the NAMUR terminal strip (option B00).........................................237 Circuit-breaker interface.......................................................................................................238 Interfaces of the Power Stack Adapter.................................................................................239 Gating of the power semiconductors....................................................................................239 Selecting Safe Torque Off....................................................................................................239 Actual value channels..........................................................................................................240 Trip line................................................................................................................................240 DRIVE-CLiQ interface..........................................................................................................240 Analog and digital outputs....................................................................................................241 Switch for the analog inputs.................................................................................................241 Analog and digital inputs and temperature sensor connections...........................................242 Electronics power supply.....................................................................................................243 Checklists and forms................................................................................................................................245 C.1 Mechanical installation: Checklist........................................................................................245 C.2 Checklist for electrical installation........................................................................................246 Index.........................................................................................................................................................251 10 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Table of contents Tables Table 3-1 Connector -X231.........................................................................................................................48 Table 3-2 Connector -X232.........................................................................................................................49 Table 3-3 Connectors -X1 and -X31............................................................................................................49 Table 3-4 Connector -X32...........................................................................................................................50 Table 3-5 Connector -X33...........................................................................................................................50 Table 3-6 Connector -X34...........................................................................................................................50 Table 3-7 Connector -X35...........................................................................................................................50 Table 3-8 Connector -X36...........................................................................................................................51 Table 3-9 Deionized water requirements.....................................................................................................54 Table 3-10 Braking power of the Braking Module with external braking resistor...........................................67 Table 3-11 Max. permissible cable lengths...................................................................................................69 Table 6-1 Dimensioning cables.................................................................................................................100 Table 6-2 Cable cross-sections.................................................................................................................101 Table 6-3 Drive and motor connection terminals.......................................................................................103 Table 7-1 PROFIBUS interface X126........................................................................................................110 Table 7-2 Description of the DP1 LEDs.....................................................................................................111 Table 8-1 List of signals for the operation screen......................................................................................124 Table 8-2 Scaling.......................................................................................................................................125 Table 8-3 Overview of important parameters (equipment commissioning)...............................................140 Table 8-4 Drive Object VectorMV..............................................................................................................142 Table 8-5 Parameter..................................................................................................................................154 Table 8-6 Parameter..................................................................................................................................154 Table 8-7 Parameter..................................................................................................................................155 Table 8-8 Parameter..................................................................................................................................156 Table 8-9 LEDs of the Power Stack Adapters ..........................................................................................176 Table 8-10 LEDs of the DM10 diagnostics module.....................................................................................177 Table 9-1 Technical specifications of the backup battery..........................................................................197 Table 9-2 Tightening torque for screws.....................................................................................................201 Table 9-3 Tightening torques for screw terminals for copper cables without cable lug 1)..........................202 Table B-1 Standards and conformity.........................................................................................................231 Table B-2 General technical specifications................................................................................................233 Table B-3 Cooling......................................................................................................................................234 Table B-4 Climatic environmental conditions.............................................................................................234 Table B-5 Mechanical ambient conditions.................................................................................................234 Table B-6 Other ambient conditions..........................................................................................................235 Table B-7 Technical specifications of the common power supply.............................................................235 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 11 Table of contents Table B-8 Technical specifications of the AD586LR reference element....................................................235 Table B-9 Terminal assignment of customer interface TM15....................................................................236 Table B-10 Terminal assignment of customer interface TM31....................................................................236 Table B-11 Terminal assignment of NAMUR terminal strip.........................................................................237 Table B-12 Terminal assignment for circuit-breaker interface .LA -X11......................................................238 Table B-13 Terminal assignment for circuit-breaker interface .LA -X52 with OFF and undervoltage coil....238 Table B-14 Terminal assignment for circuit-breaker interface .LA -X52 with two OFF coils and undervoltage coil.......................................................................................................................238 Table B-15 Terminal assignment for circuit-breaker interface .LA -X52 with capacitor release..................238 Table B-16 Power Stack Adapter 2: Actual value channels.........................................................................240 Table B-17 Power Stack Adapter 2: Trip line...............................................................................................240 Table B-18 DRIVE-CLiQ interface...............................................................................................................240 Table B-19 Power Stack Adapter 2: Analog and digital outputs..................................................................241 Table B-20 Power Stack Adapter 2: Switch for the analog inputs...............................................................241 Table B-21 Power Stack Adapter 2: Analog and digital inputs and temperature sensor connections.........242 Table B-22 Power Stack Adapter 2: Electronics power supply....................................................................243 Figures Figure 3-1 Design of the power unit..............................................................................................................34 Figure 3-2 Basic Line Module with diodes in 12-pulse configuration............................................................35 Figure 3-3 Phase module.............................................................................................................................36 Figure 3-4 Overview of PSA interfaces.........................................................................................................41 Figure 3-5 AVT combination module............................................................................................................42 Figure 3-6 Design when using IGCTs...........................................................................................................43 Figure 3-7 Overview ....................................................................................................................................44 Figure 3-8 Logical design of the DM10 diagnosis module............................................................................46 Figure 3-9 Printed circuit board of the diagnostics module...........................................................................47 Figure 3-10 Circuit diagram option L10..........................................................................................................60 Figure 3-11 Connecting the motor to the dv/dt filter.......................................................................................61 Figure 3-12 Circuit diagram option L11..........................................................................................................62 Figure 3-13 Connecting the motor to the sine-wave filter...............................................................................70 Figure 4-1 Example of attaching and displaying the shock and tilt indicators..............................................73 Figure 4-2 Example illustration of centers of gravity.....................................................................................75 Figure 4-3 Lifting bar label............................................................................................................................77 Figure 4-4 Securing the lifting rods...............................................................................................................78 Figure 4-5 Transporting a transportation unit (still in packaging) with a crane.............................................79 Figure 4-6 Example: Label with instructions for opening the doors..............................................................81 Figure 4-7 Example: Cover screw for manual door interlocking...................................................................81 Figure 5-1 Connecting two transportation units............................................................................................87 12 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Table of contents Figure 5-2 Connecting four transportation units...........................................................................................87 Figure 5-3 Connecting cabinets....................................................................................................................89 Figure 5-4 DC-bus connection......................................................................................................................91 Figure 5-5 Example: Connecting interface terminals ...................................................................................92 Figure 5-6 Remove the screws.....................................................................................................................93 Figure 5-7 Install battery...............................................................................................................................94 Figure 6-1 Shield connection using a clip.....................................................................................................99 Figure 6-2 Bridging shield gaps....................................................................................................................99 Figure 6-3 Potential concept.......................................................................................................................100 Figure 6-4 Example: Connecting the power cables....................................................................................102 Figure 6-5 Connection of the supply-system power cable..........................................................................103 Figure 6-6 Grounding lug............................................................................................................................104 Figure 6-7 Connection for auxiliary voltages..............................................................................................105 Figure 6-8 Connecting the external encoder to the SMC30 Sensor Module..............................................107 Figure 6-9 Connection example 1: HTL encoder, bipolar, with reference signal........................................107 Figure 6-10 Schematic diagram: Fastening the cable ties............................................................................108 Figure 7-1 PROFIBUS interface.................................................................................................................110 Figure 7-2 X126 PROFIBUS connection....................................................................................................110 Figure 7-3 PROFIBUS address switch cover.............................................................................................111 Figure 7-4 PROFIBUS connectors.............................................................................................................112 Figure 7-5 Position of the bus terminating resistors...................................................................................112 Figure 8-1 AOP30 operator panel...............................................................................................................117 Figure 8-2 Menu structure of the AOP 30...................................................................................................119 Figure 8-3 Function keys of the AOP 30.....................................................................................................120 Figure 8-4 Example of the operation screen...............................................................................................121 Figure 8-5 Menu structure of the operation screens...................................................................................131 Figure 8-6 Parameterization menu structure..............................................................................................133 Figure 8-7 Selecting data sets....................................................................................................................135 Figure 8-8 Menu structure for fault memory/alarm memory.......................................................................136 Figure 8-9 Alarm screen.............................................................................................................................138 Figure 8-10 Commissioning / service / device commissioning menu structure............................................138 Figure 8-11 Commissioning / service / drive commissioning menu structure...............................................142 Figure 8-12 Commissioning /Service / AOP settings menu structure...........................................................143 Figure 8-13 Commissioning / Service / AOP diagnostics menu structure....................................................147 Figure 8-14 Language menu structure.........................................................................................................151 Figure 8-15 Parameter types........................................................................................................................152 Figure 8-16 Switchover conditions................................................................................................................158 Figure 8-17 Operating areas and characteristic curves for the induction motor with drive supply...............159 Figure 8-18 Example: Setting analog output 0.............................................................................................162 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 13 Table of contents Figure 8-19 Potential supply of external signals...........................................................................................164 Figure 8-20 Digital signal output to the system I/O.......................................................................................165 Figure 9-1 Grounding points.......................................................................................................................187 Figure 9-2 Example: Attaching the grounding spider..................................................................................188 Figure 9-3 Make-proof-grounding switch closed.........................................................................................189 Figure 9-4 Principle of the mechanical door interlock.................................................................................191 Figure 9-5 Components of the secure locking system................................................................................191 Figure 9-6 Schematic diagram: Replacing filter mats.................................................................................195 Figure 9-7 Changing the filter in the roof assembly....................................................................................196 Figure 9-8 Replacing the backup battery....................................................................................................197 Figure 9-9 Attaching the changing device to the forklift truck.....................................................................203 Figure 9-10 Attaching the changing device to the forklift truck.....................................................................204 Figure 9-11 Lifting solenoid..........................................................................................................................205 Figure 9-12 Water connection......................................................................................................................205 Figure 9-13 Fiber-optic conductors and power supply cable........................................................................206 Figure 9-14 Busbar package........................................................................................................................206 Figure 9-15 Motor current acquisition module..............................................................................................206 Figure 9-16 Busbar.......................................................................................................................................207 Figure 9-17 Installing the busbars................................................................................................................207 Figure 9-18 Insulators of the phase module and lifting lugs.........................................................................208 Figure 9-19 Changing device: roller tracks...................................................................................................208 Figure 9-20 Changing device: joining the roller tracks..................................................................................209 Figure 9-21 Changing device: stop brackets................................................................................................209 Figure 9-22 Phase module (placed down)....................................................................................................210 Figure 9-23 Diode module: water connection...............................................................................................212 Figure 9-24 Diode module: phase connections............................................................................................212 Figure 9-25 Diode module: insulators...........................................................................................................213 Figure 9-26 Diode module: lugs....................................................................................................................213 Figure 9-27 Changing device: roller tracks...................................................................................................213 Figure 9-28 Changing device: joining the roller tracks..................................................................................214 Figure 9-29 Changing device: stop brackets................................................................................................214 Figure 9-30 Replacing the operator panel....................................................................................................215 Figure 9-31 Replacing the precharging transformer.....................................................................................217 Figure 9-32 Replacing the precharging rectifier............................................................................................218 Figure 9-33 Example of an AVT combination module..................................................................................219 Figure 9-34 Sponge......................................................................................................................................220 Figure 9-35 Replacing the sponge................................................................................................................221 Figure B-1 24-pulse supply with series connection of two Basic Line Modules..........................................232 14 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Table of contents Figure B-2 Performance enhancement with parallel operation of three complete drive units 1); 36-pulse supply possible..........................................................................................................................232 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 15 Table of contents 16 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 1 Introduction 1.1 About these instructions These instructions describe the drive and explain how to handle it, from initial delivery to final disposal of the equipment. Keep these instructions for later use. Read these instructions before you handle the drive and follow the instructions. The instructions contain information about the safe handling of the drive as well as its components and modules. They provide information on assembling, installing, and maintaining the equipment properly. If you have suggestions for improving the document, please contact our Service Center (Page 229). Text format features The warning notice system is explained on the rear of the inside front. Always follow the safety instructions and notices in these instructions. In addition to the safety-related warning notices which you must read, you will find the text in these instructions is formatted in the following way: 1. Handling instructions are always formatted as a numbered list. Always perform the steps in the order given. Lists are formatted as bulleted lists. - Lists on the second level are hyphenated. Note A Note is an important item of information about the product, handling of the product or the relevant section of the document. Notes provide you with help or further suggestions/ideas. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 17 Introduction 1.1 About these instructions 18 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 2 Safety instructions In the individual chapters of this document, you will find safety instructions that must be obeyed absolutely, for your own safety, to protect other people and to avoid damage to property. Pay attention to the following safety instructions for all activities on the inverter. 2.1 Warning symbol on the device Please observe the warning symbols attached to the device. The warning symbols have the following meaning: Warning symbol Meaning Warning: Voltage Warning: Hot surface General warning symbol: Observe the explanations about the hazard on the device labels. For transportation, observe the "transportation markings (Page 74)" on the device packaging. 2.2 Qualified personnel The product/system described in this documentation may only be operated by personnel qualified for the specific task in accordance with the relevant documentation for the specific task, in particular its warning notices and safety instructions. Because of their training and experience, qualified personnel can recognize any risks involved with handling these products/ systems and avoid any possible dangers. 2.3 The five safety rules For your own personal safety and to prevent material damage when carrying out any work, always observe the safety-relevant instructions and the following five safety rules according to EN 501101 "Working in a voltage-free state". Apply the five safety rules in the sequence stated before starting work. Five safety rules 1. Disconnect the system. Also disconnect the auxiliary circuits, for example, anti-condensation heating. 2. Secure against reconnection. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 19 Safety instructions 2.4 Safe handling 3. Verify absence of operating voltage. 4. Ground and short-circuit. 5. Provide protection against adjacent live parts. To energize the system, apply the measures in reverse order. 2.4 Safe handling WARNING High voltages from external supplies Even if the circuit breaker is open, parts of the drive can be under voltage (live) as a result of the auxiliary voltage at the premagnetization, precharging or demagnetization transformers. This danger is not limited to the drive, but can also occur with components that are electrically connected to the drive (e.g. circuit breakers or isolators). Touching live parts can result in death, serious injury, and damage to property. Isolate all components that can feed voltage to the converter before commencing work. WARNING High voltages during operation When operating this equipment very high voltages develop. Even after switching off the mains voltage, or while the connected machine is still turning, high voltages can remain for a prolonged length of time. High voltages can cause death or serious injury if the safety rules are not observed or if the equipment is handled incorrectly. Operate the drive properly. Always follow the "The five safety rules (Page 19)" when performing any work. Only remove the covers using the methods described by these operating instructions. Maintain the drive regularly and correctly. WARNING High voltages from machines still turning and connected Rotating machinery can induce dangerous high voltages and synchronous motors that are not de-excited immediately can also pose a hazard. If the connection to the motor is not isolated or grounded, these voltages can also remain. Touching live parts can result in death or serious injury. Before opening the doors, wait until the connected machine has come to a standstill. 20 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Safety instructions 2.4 Safe handling WARNING High voltages from DC link capacitors High voltages are still present at the DC link capacitors even after shutdown. Touching live parts can result in death or serious injury. A label on the converter specifies the discharge times of the DC link capacitors. Only open the converter once these discharge times have expired. Observe the five safety rules when performing any work. WARNING High auxiliary voltages High auxiliary voltages are still present even after shutdown. Touching live parts can result in death or serious injury. Observe the five safety rules when performing any work. WARNING Hazardous arcing Hazards caused by arcing can occur as result of the following factors, for example: The input currents are exceeded Incorrectly dimensioned circuit breaker or transformers Incorrectly connected cables or cables that have not been connected Excessive pollution Arcing can result in death, serious injury or material damage. Make sure that the system is properly dimensioned and that the power cables are correctly connected. The maximum permissible input currents are listed in the "Technical specifications". Remove any excessive pollution. WARNING Live, moving or rotating parts Contact with the parts mentioned can result in death, serious physical injury or damage to property. Observe the instructions regarding installation and operation. Always take protective measures before touching any components. Do not remove any necessary covers. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 21 Safety instructions 2.4 Safe handling WARNING Hot component surfaces Certain components (e.g. heat sinks and reactors) can become very hot during operation. These components can remain hot for a long time after operation. Contact can result in serious injury, such as skin burns. Do not touch hot components even after you have switched off the drive. WARNING Hot anti-condensation heating surface When the temperature control limit value is reached the anti-condensation heating is switched on. Once activated, the anti-condensation heating can generate a great deal of heat. Contact can result in serious injury, such as skin burns. Ensure that the anti-condensation heating cannot be touched. Ensure that the anti-condensation heating is switched off before carrying out any repair or maintenance work. CAUTION Places that are difficult to access If you do not use appropriate protective equipment when working in places that are difficult to access you are at risk of injury. For example, sharp edges and splinters can cause injuries to the head and skin. If you use unsuitable steps when working on the upper areas of the drive, you can fall and injure yourself. Use appropriate protective equipment, especially a hard hat and gloves. In the upper areas of the drive, use suitable steps. CAUTION 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. 22 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Safety instructions 2.5 Electromagnetic fields in electrical power engineering installations NOTICE Unsuitable residual current monitoring device If you operate the drive together with a residual current monitoring device (RCD), it is possible the residual current monitoring device will trip in error (nuisance trip). The drive may be switched off as a result of the protection device tripping in error. To minimize the risk of faulty trips, use a type-B RCD. 2.5 Electromagnetic fields in electrical power engineering installations Electromagnetic fields are generated during operation of electrical power engineering installations. Electromagnetic fields can interfere with electronic devices, These devices can malfunction if electromagnetic fields are present. WARNING Interference with pacemakers The functioning of cardiac pacemakers could be impaired by electromagnetic fields. Death or serious physical injury can result. It is therefore not permissible for people with pacemakers to stand close to the converter. NOTICE Data loss Electromagnetic fields can cause data loss to magnetic or electronic data storage media. Therefore, do not carry magnetic or electronic data storage media with you. Nominated persons in control of electrical installations can find further information on electromagnetic fields under "Information for persons responsible for plants and systems." SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 23 Safety instructions 2.6 Components that can be destroyed by electrostatic discharge (ESD) 2.6 Components that can be destroyed by electrostatic discharge (ESD) ESD guidelines NOTICE Electrostatic discharge Electronic components can be destroyed in the event of improper handling, transport, storage, and shipping. Pack the electronic components in appropriate ESD packaging; e.g. ESD foam, ESD packaging bags and ESD transport containers. To protect your equipment against damage, follow the instructions given below. Avoid physical contact with electronic components. If it is essential that you perform work on these components, you must wear one of the following pieces of protective gear: - Grounded ESD wrist strap - ESD shoes or ESD shoe grounding strips if there is also an ESD floor. Do not place electronic components close to data terminals, monitors or televisions. Maintain a minimum clearance to the screen (> 10 cm). Electronic components should not be brought into contact with electrically insulating materials such as plastic foil, plastic parts, insulating table supports or clothing made of synthetic fibers. Bring components into contact only with ESD-compliant materials, e.g. ESD tables, ESD surfaces, ESD packaging. Only carry out measurements on the components if one of the following conditions is met: - The measuring device is grounded with a protective conductor, for example. - The measuring head of a floating measuring device has been discharged directly before the measurement. The necessary ESD protective measures for the entire working range for electrostatically sensitive devices are illustrated once again in the following drawings. Precise instructions for ESD protective measures are specified in the standard DIN EN 6134051. 24 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Safety instructions 2.7 Information for nominated persons in control of an electrical installation Sitting a d ESD clothing Conductive floor cover ing 1) Standing b ESD furniture e ESD wrist strap Standing/sitting c Wearing of ESD shoes or f ESD shoe grounding strips 2) Cabinet ground connection 1) Only effective in conjunction with ESD shoes or ESD shoe grounding strips 2) Only effective in conjunction with conductive floor covering 2.7 Information for nominated persons in control of an electrical installation 2.7.1 Proper usage The converters are intended to be used as a stationary installation in closed and dry rooms with a clean atmosphere. You can find the ambient and operating temperatures to be adhered to in the technical data. If the described environmental conditions are not observed, warranty claims and other claims may be rejected. WARNING Explosions If you operate the converter in a potentially explosive atmosphere, explosions can occur which can cause death, serious injuries or material damage. Only operate the converter in a non-explosive environment (no hazardous zones). WARNING Non-observance of proper usage Improper use of the devices described can result in death, severe injury or material damage. Please observe all instructions for proper use. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 25 Safety instructions 2.7 Information for nominated persons in control of an electrical installation The nominated person in control of an electrical installation must ensure that the following points are observed: Follow the local and industry-specific safety and setup regulations. Observe the requirements in the guidelines specified in the "Standards and regulations" section of the "Technical data and drawings." Ensure that the specific safety and construction regulations and the regulations for using personal protective equipment are observed during all work. The operating instructions and the complete product documentation are always available when carrying out any work. The technical data as well as the specifications relating to the permissible installation, connection, ambient and operating conditions are taken into account at all times. Only qualified personnel or personnel supervised by responsible, skilled specialists are allowed to carry out basic planning and all work on the converter. During shipping, specific transport conditions are adhered to. Assembly is performed according to assembly instructions. Separate cabinet units are connected properly (cables and busbars). All instructions for EMC-compatible installation, cabling, shielding, grounding, and for adequate auxiliary power supply are to be observed. Commissioning is only to be performed by qualified personnel trained for that purpose in accordance with the commissioning instructions. System configuration is carried out by an experienced system integrator. Further system components such as the circuit-breaker, transformer, cables, and motor are adjusted for converter operation. The converter is only operated in conjunction with the engineered components. Different operating modes, overloads, load cycles, and differing environmental conditions are permitted only after special arrangement with the manufacturer. Note Make use of the support and services offered by the relevant service center for planning, installation, commissioning, and servicing work. You can find the relevant contact person under "Service & Support". 2.7.2 Security information Siemens provides products and solutions with industrial security functions that support the secure operation of plants, systems, machines, and networks. In order to protect plants, systems, machines and networks against cyber threats, it is necessary to implement - and continuously maintain - a holistic, state-of-the-art industrial security concept. Siemens' products and solutions only form one element of such a concept. Customer is responsible to prevent unauthorized access to its plants, systems, machines and networks. Systems, machines and components should only be connected to the enterprise network or the internet if and to the extent necessary and with appropriate security measures (e.g. use of firewalls and network segmentation) in place. 26 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Safety instructions 2.7 Information for nominated persons in control of an electrical installation Additionally, Siemens' guidance on appropriate security measures should be taken into account. You can find more information about industrial security by visiting: http://www.siemens.com/industrialsecurity. Siemens' products and solutions undergo continuous development to make them more secure. Siemens strongly recommends to apply product updates as soon as available and to always use the latest product versions. Use of product versions that are no longer supported, and failure to apply latest updates may increase customer's exposure to cyber threats. To stay informed about product updates, subscribe to the Siemens Industrial Security RSS Feed under http://www.siemens.com/industrialsecurity. 2.7.3 Grounding concept Create a grounding concept and integrate the converter within it. The grounding concept must take into consideration national provisions and system specifics. Ensure that the following criteria are fulfilled: Screw together the converter sub-units at the installation site, ensuring good conductivity. If shield busbars are provided, these must be connected together. When the converter is supplied with power, the protective ground conductor must be connected to the system's grounding point. Select the cross-section of the protective ground conductor from one of the following variants: - According to local wiring regulations - Calculated according to IEC 60364-5-54, 543.1 - Half a phase conductor cross-section 2.7.4 Installation site safety WARNING Unsafe installation sites This drive is used in industrial high-voltage installations. Improper use, incorrect operation, insufficient maintenance, and access by unauthorized persons can lead to accidents. The results can be death, serious bodily injury or damage to property. Install the drive in electrical rooms where only qualified personnel have access. If this is not possible, then ensure that a barrier prevents uncontrolled access. Use safety fences and appropriate signs, for example, to prevent unauthorized entry to the zone that has been fenced off. Put up notices which indicate that only trained personnel are allowed to operate the drive and carry out maintenance and repair work. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 27 Safety instructions 2.8 Residual risks Note Installations that include converters must be equipped with additional monitoring and protective devices to fulfill safety requirements. Follow technical equipment legislation and accident prevention regulations. Note The converter will be supplied on request without an electromechanical door interlocking system if space is restricted. In this instance, the customer must provide an access interlock system compliant with IEC 61800-5 /-1. Note The drive does not have a grounding breaker at the input/output. The system operator must, therefore, ensure that there is sufficient grounding. 2.7.5 Measures for operator protection in electromagnetic fields The plant operator is responsible for taking the following appropriate measures (labels and hazard warnings) to adequately protect operating personnel against any possible risk. Observe the relevant nationally applicable health and safety regulations or the applicable national regulations in the country of installation. In Germany, "electromagnetic fields" are subject to regulations BGV B11 and BGR B11 stipulated by the German statutory industrial accident insurance institution. Display adequate hazard warning notices on the installation. Place barriers around hazardous areas. Take measures, e.g. using shields, to reduce electromagnetic fields at their source. Make sure that personnel are wearing the appropriate protective gear. 2.8 Residual risks According to the EU machinery directive, machine manufacturers / plant operators must conduct a risk assessment of their machine. Plant operators must conduct a risk assessment of their plant. In particular, pay attention to Annex 1 "General Principles" of the EU machinery directive. 28 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Safety instructions 2.8 Residual risks Pay attention to the following residual risks: Unintentional movements of driven machine parts Unintentional movements of driven machine parts can occur during commissioning, operation, maintenance, and repair, e.g. from the following causes: - Hardware defects and/or software errors in the sensors, controllers, actuators, and connection technology - Response times of the controller and drive - Operating and/or environmental conditions outside of the specification - Condensation/conductive contamination - Parameterization, programming, cabling, and installation errors - Use of radio devices/cell phones in the immediate vicinity of the controller - External influences/damage High temperatures and emissions A fault can occur as a result of the following, for example: - Component malfunctions - Software errors - Operating and/or environmental conditions outside of the specification - External influences/damage A fault can, for example, have the following consequences both inside and outside the drive: - Extraordinarily high temperatures, including open fires as a result of the fault - Emissions of light, noise, particles or gases Converters with open type/IP20 protection must be installed in a distribution station or comparable environment. Hazardous shock voltages Hazardous shock voltages can result from the following causes, for example: - Component malfunctions - Induction of voltages in moving motors - Operating and/or environmental conditions outside of the specification - Condensation/conductive contamination - External influences/damage The release of substances and emissions that are harmful to the environment Improper operation or the improper disposal of components can harm the environment. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 29 Safety instructions 2.8 Residual risks Damage from pressure build-up during electric arcs in the event of a fault If the dimensions of the building have not been designed correctly for the drive, damage can result from the pressure that may build up inside. Dangerous electric arcs during internal faults The drives are designed according to the relevant IEC standards and have been tested in line with strict type-testing procedures. They were developed and manufactured so that there is a very low probability of internal faults occurring. However, internal faults cannot be completely ruled out. WARNING Dangerous electric arcs during internal faults Defects such as damage to components, overvoltages, or loose parts, as well as exceptional operating statuses, can cause a failure within the enclosure. This can result in an internal electric arc. If an electric arc occurs and people are nearby, this could lead to death, serious physical injury, and damage to property. Ensure that only qualified personnel perform work on the drive. Observe the safety and operating instructions in this documentation and on labels at the drive for all work on the drive. Note There are no standards for medium-voltage drives stipulating requirements or inspections for electric arc resistance. There is therefore neither formal guidance provided nor formal certification available with regard to electric arc resistance. 30 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Description 3.1 3 Applications The drive is a medium-voltage drive for phase-rotation-controlled machines. The drive is a single drive designed for applications with a quadratic, constant load characteristic and no regenerative feedback. Typical applications include pumps, fans, compressors, extruders, mixers, and mills. Note For the output range of the drive, see "Technical specifications". See also Technical data and drawings (Page 231) 3.2 Safety concept The converter and its components are subject to a comprehensive 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 converter is also equipped with monitoring functions to protect external components. The converter operates safely when the interlock and protection systems are functioning properly. Nevertheless, there are areas on the converter that are hazardous for personnel and that cause material damage if the safety information of all the instructions and the labels on the converter are not strictly observed. 3.2.1 Safety components and functions The drive has the following safety components and functions to protect personnel: The make-proof grounding switch for grounding the voltage DC link. The electromechanical door interlock system prevents access to the power unit while the drive is in operation. The doors cannot be opened until the grounding switch has been closed. The door for the control section, however, can be opened for monitoring purposes even during operation. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 31 Description 3.2 Safety concept The electromechanical interlock system for the make-proof grounding switch prevents the make-proof grounding switch from closing for the voltage DC link. The make-proof grounding switch can only be closed if the circuit-breaker is open and the DC link has been completely discharged. The EMERGENCY OFF mushroom pushbutton in the cabinet door is a pushbutton with mechanical interlock system for EMERGENCY OFF, Stop Category 0 (standard). Note As option, the make-proof grounding switch also serves to ground the input side (option L48) and the output side (option L49). 3.2.2 External safety components The drive has the following external safety components for the safety concept: Circuit breaker More detailed information is provided in Chapter Circuit-breaker (provided by the customer) (Page 38). Input-side transformer The transformer on the input side must be configured in such a way that the maximum shortcircuit current is not exceeded. Information on this is provided in the technical data sheet of the transformer. 3.2.3 Protection and monitoring functions of internal components The internal components of the drive have the following protection and monitoring functions: Crowbar Drive protection based on monitoring systems: - Current monitoring - DC-link monitoring - Output voltage monitoring - Thermal monitoring of the power unit - Precharge monitoring - Insulation monitoring - Supply voltage monitoring - GSV monitoring - Circuit-breaker monitoring - Re-cooling unit monitoring 32 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Description 3.3 Design Shutdown in the event of semiconductor failure Shutdown in the event of control component failure Internal protection functions for the control hardware Protection against communication failure between the closed-loop control and the power unit Anti-condensation heating 3.2.4 Protection and monitoring functions for external components Transformer and motor can be monitored in the drive. A fast protective shutdown that you can activate for external problems, e.g. short-circuits, is present. 3.3 Design 3.3.1 Components The drive in the basic configuration is equipped with the following components: 12-pulse Basic Line Module DC link Motor Module An optional 24-pulse Basic Line Module is also available for other configurations. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 33 Description 3.3 Design The drive is a three-level voltage DC-link drive. N9a+] a a 1 Circuit-breaker 5 Motor Module (3-level inverter) with IGCT 2 Drive transformer 6 Motor-side voltage/current transformers 3 Basic Line Module (diode rectifier) 7 High-voltage motor 4 DC link with dry-type capacitors Figure 3-1 3.3.2 Design of the power unit Design of the Basic Line Module In a 12-pulse configuration, the Basic Line Module consists of a rectifier module. In a 24-pulse configuration, the Basic Line Module comprises two rectifier modules. 34 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Description 3.3 Design Motor Module and Braking Module units can be connected to the Basic Line Module via the DC bus. Figure 3-2 Basic Line Module with diodes in 12-pulse configuration A rectifier module consists of two B6 diode bridges connected in parallel. 12 disk-type thyristors installed in the module are arranged in a clamped stack. Each diode is equipped with an RC circuit. 3.3.3 Design of the Motor Module The Motor Module comprises three identical phase modules. On each phase module, four IGCT power semiconductors are located between water-cooled heat sinks to ensure adequate cooling on both sides of the components. In addition, four freewheeling diodes, two neutral-point diodes and two clamp circuits are installed in each phase module. The clamp circuits comprise the following components: Switch-on relief choke Snubber capacitor Snubber diode Snubber resistor The switch-on relief chokes are located on the side of the phase module. The snubber capacitors and resistors are located in the lower area of the phase module. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 35 Description 3.4 Operating principle Block diagram of phase module Phase module Figure 3-3 Phase module The DC-link capacitor bank is connected to the individual phase modules through a lowinductance flat busbar. The low-inductance flat busbar is constructed as busbar package. The individual busbars and insulation layers are glued or screwed together. 3.3.4 Gating The gating group and the GCT (Gate-Commutated Thyristor) power semiconductor together form a fixed unit, the IGCT (Integrated Gate-Commutated Thyristor). The power semiconductors are connected via the gating boards. The gating command is transmitted from the power stack adapter (PSA) to the gating board via a plastic fiber-optic cable connection. 3.4 Operating principle A constant DC-link voltage for the Motor Module is generated from the line voltage. The Motor Module provides the power for the connected motor via the DC-link voltage. 36 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Description 3.5 Description of the components The DC link capacitors smooth the voltage and stop the energy in the DC link. The DC link capacitors are maintenance free and self-healing. The drive is switched off when the circuitbreaker is disconnected. The DC link is discharged by means of balancing resistors. 3.5 Description of the components 3.5.1 SINAMICS Control Unit The CU320-2 DP Control Unit is the central control module of the drive's open-loop and closedloop control system. The connections are wired internally to the customer terminal block. Further information is available in the following documents: You will find information on the wiring in the circuit manual in the "Technical specifications and drawings" appendix. You can find information on the interfaces and LEDs in the "Supplementary component descriptions" document. See also Technical data and drawings (Page 231) 3.5.2 Terminal Modules The Terminal Modules are the central interface for digital and analog inputs and outputs. You can optionally expand the interface to include additional Terminal Modules. 3.5.3 Precharging To prevent overcurrents and temporary overvoltages in the DC link when the line voltage is connected, the DC-link capacitors must be precharged. 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 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 37 Description 3.5 Description of the components Detailed information about interconnecting the precharging components is provided in the circuit manual. The component mounting locations are provided in the layout diagram. Designation Value Precharging time 1) 25 s Precharging current in three-phase 400 V supply 20 A Discharging time of the DC link TDISCH 300 s 1) 3.5.4 1) The time can vary depending on the system Electromechanical door interlock system The electromechanical door interlock system is designed to protect personnel, and is an integral part of the safety concept. During operation and when the make-proof grounding switch is open, all the doors are interlocked (with the exception of the door for the control section). The electromechanical door interlock system ensures that the doors for the power unit cannot be opened when the DC link voltage is above a defined threshold value. The control only releases the door interlocking once the circuit breaker is safely open and the grounding switch is closed. You can open the doors once released by the control. The device cannot be switched on again until all the doors are closed. The doors remain interlocked if the auxiliary voltage fails. For more information, refer to the Chapter "Maintenance" See also Opening the doors (Page 189) 3.5.5 Make-proof grounding switch The make-proof grounding switch grounds the voltage DC link. This ensures that no hazardous voltages are present in the DC link when the doors are opened. To ensure that the drive functions safely, the actuating lever for the make-proof grounding switch must be removed. 3.5.6 Circuit-breaker (provided by the customer) To ensure adequate protection for converters, the circuit-breaker provided by the customer must fulfill the following requirements: The maximum time between when the circuit-breaker trips to when a no-current state (I=0) is reached is 80 ms. The circuit breaker must be equipped with an undervoltage tripping function. Avoid additional delay times when controlling the circuit breaker. All commands from the converter to the circuit breaker must act directly without intervention of coupling relays. 38 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Description 3.5 Description of the components A feedback signal must be available for each of the circuit-breaker states CLOSED and OPEN. The feedback signals must not be delayed. Consequently, do not use any coupling relays. The circuit-breaker is controlled and released from the converter closed-loop control. If this has not been enabled, under no circumstances should you switch on the circuit-breaker by external mechanical or electrical means. To protect the converter transformer, ensure that overcurrent protection is in place. 3.5.7 Converter transformer A three-winding transformer is required for the 12-pulse Basic Line Module. The secondary windings of the three-winding transformer have a phase shift of 30el, which results in a 12pulse supply with correspondingly lower line harmonics. With a 24-pulse Basic Line Module, two three-winding transformers are required. The additional shifting of the primary-side windings for the two transformers by +7.5 or -7.5 allows a 24-pulse supply to be generated. Instead of the two three-winding transformers, a fivewinding transformer can be used (after consultation with the transformer manufacturer). Consider the following properties during the configuration: Short-circuit voltage uk 10% (in relation to 10 MVA) Transformer taps for voltage adjustments: 2 x 2.5%. The winding transformer taps are normally located on the primary side of the transformer. The voltages and insulation for the secondary-side windings must be dimensioned as shown in the following table: Connection Single connection Connection version (see "Technical specifications") Basic connection, 12-pulse infeed Series connection of the Basic Line Module Infeed transformers 1 three-winding transformer 2 three-winding transformers Recommended vector group Dy5 Dd0 Dy5 Dd0 with primary shift + 7.5 Dy5 Dd0 with primary shift - 7.5 Converter output voltage [kV] Test voltage [kV] 1) Transformer secondary voltage (no-load voltage) [kV] 3.3 33.6 2 x 1.7 2) 2 x 0.85 (2x) 3) The specified voltage is the required impulse withstand / test voltage for the transformer secondary windings with respect to ground. Because the transformers generally have temperature evaluation systems in the windings, the specified test voltage is required for strengthened insulation. If no control circuits have been installed in the windings, the test voltage in accordance with the basic insulation is sufficient. 1) SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 39 Description 3.5 Description of the components 3.5.8 2) Basic connection 3) Option Power Stack Adapter 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. 40 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Description 3.5 Description of the components X11 - X14 Gating of the power semiconductors, inverter phase u X15, X16, Gating of the power semiconductors, crowbar X31 - X34 Gating of the the power semiconductors, inverter phase v X35, X36 Gating of the power semiconductors, braking chopper X51 - X54 Gating of the power semiconductors, inverter phase w X241, X242 Selecting Safe Torque Off X70 - X79 Actual value channels 0 to 9 X81 Trip line X200 - X202 DRIVE-CLiQ interfaces X231, X232 Analog and digital outputs S5.0 Switches of the analog inputs, voltage/current measurement AI0 S5.1 Switches of the analog inputs, voltage/current measurement AI1 X221, X222 Analog and digital inputs, temperature sensor connections LEDs Diagnostics via LEDs X210 Electronics power supply Figure 3-4 Overview of PSA interfaces See also Gating of the power semiconductors (Page 239) Selecting Safe Torque Off (Page 239) Actual value channels (Page 240) Trip line (Page 240) SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 41 Description 3.5 Description of the components DRIVE-CLiQ interface (Page 240) Analog and digital outputs (Page 241) Switch for the analog inputs (Page 241) Analog and digital inputs and temperature sensor connections (Page 242) LEDs of the Power Stack Adapters (Page 176) Electronics power supply (Page 243) 3.5.9 Actual value acquisition Actual current and voltage values are recorded by the AVT combination module . The AVT combination module converts analog signals into digital signals and forwards them to the PSA. The signals are transferred to the PSA via fiber-optic cables. Figure 3-5 AVT combination module The AVT combination is installed in the power unit. 3.5.10 Common power supply 3.5.10.1 Field of application The common power supply (GSV) is an AC/AC converter that converts an alternating voltage into a square-wave voltage. You can select one of the following rated voltages with associated rated frequencies for the alternating input voltage: 1-phase 115 VAC / 60 Hz 1-phase 230 VAC / 50 Hz / 60 Hz 1-phase 240 VAC / 50 Hz / 60 Hz 42 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Description 3.5 Description of the components On the front panel of the device there is a labeled switch with which the rated voltage can be selected with the aid of a screwdriver. The square-wave voltage of 55 V generated from the input voltage supplies four power outputs with equality of access. The design principle differs according to which electronic component is to be supplied with the aid of the GSV. Each power output is monitored for undervoltage. When the voltage level of all power outputs is within the standard range, the LED signaling the status indication lights up green. The device 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. See also Technical specifications of the common power supply (Page 235) 3.5.10.2 Design $&9+] $&9+]+] $&9+]+] &RPPRQSRZHU VXSSO\ 9 6DIHW\WUDQVIRUPHU $FWXDOYDOXH DFTXLVLWLRQ 6DIHW\WUDQVIRUPHU 6ZLWFKLQJPRGXOH 6DIHW\WUDQVIRUPHU 6ZLWFKLQJPRGXOH 9 9 ,*&7 9 Figure 3-6 ,*&7 Design when using IGCTs SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 43 Description 3.5 Description of the components 3.5.10.3 Connections LED display for the power output Operating display Power outputs Figure 3-7 3.5.10.4 Signaling Line connection Line voltage selection Overview Interface description Tasks of the interfaces Connector Task X1 Line connection X2 Signaling X6 / X7 / X8 / X9 Power output Signal assignment of the interfaces 44 Connector/pin Signal X1.3 L X1.4 Not assigned X1.5 N X1.6 Not assigned X1.7 PE X2.4 Undervoltage REL_A X2.5 Undervoltage REL_B SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Description 3.5 Description of the components Connector/pin Signal X2.6 Presence of output voltage REL_A X2.7 Presence of output voltage REL_B X6.1 / X7.1 / X8.1 / X9.1 PE X6.2 / X7.2 / X8.2 / X9.2 P-GRD X6.3 / X7.3 / X8.3 / X9.3 55 V 3.5.11 DM10 diagnostics module 3.5.11.1 Functions The DM10 diagnosis module performs the following functions: Monitoring the auxiliary voltages of the internal 1P24 and 1N24 power supply. Monitoring the external voltage 2P24_1 and the optional external voltage 2P24_2 for undervoltage. Monitoring the auxiliary contacts of the 24 V DC miniature circuit-breakers. Output of eight binary control signals. The logic state of the signal in each case is indicated by an LED. Output of eight analog signals to the following signal receivers: - PADU8 - Indicating instruments - Control station/I&C Supply of the digital and analog signals to measuring sockets for simplified diagnosis with an oscilloscope. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 45 Description 3.5 Description of the components 6,723SRZHUVXSSO\ 3RZHU6WDFN$GDSWHU36$ '2BWR'2B $2BWR$2B ; ; SLQFRQQHFWRU &DEOH[[ ; ; ',BWR',B $,BWR$,B ,QWHUQDO SRZHUVXSSO\DQG PRQLWRULQJ '2B(WR'2B( '2BWR'2B $2BWR$2B ; '2BWR'2B ; ',B(WR',B( ; ; &RQWUROVLJQDOVIURP 36$ 3RZHU6XSSO\ 2. ; 6WDWXVVLJQDOWRFORVHG ORRSFRQWUROV\VWHP ; ',BWR',B 2SWLRQ* 5HDGLQELQDU\SODQWVLJQDOVIRUGLDJQR VLVRQ3$'8 $ 3URFHVVGDWDDFTXLVLWLRQV\VWHP 3$'8 % [ 2SWLRQ.. DQDORJ PHDVXULQJ LQVWUXPHQWV Figure 3-8 ([WHUQDO SRZHUVXSSO\DQG PRQLWRULQJ 7HVWVRFNHWV SLQFRQQHFWRU &DEOH[[ $,BWR$,B ; ; SLQFRQQHFWRU &DEOH[[ ; ; ',BWR',B $,BWR$,B /('V ; ; SLQFRQQHFWRU &DEOH[[ '0GLDJQRVLV PRGXOH $2BWR$2B 3B 3B 0 3 1 0 '2BWR'2B $2BWR$2B &RQWURO VWDWLRQ , & Logical design of the DM10 diagnosis module See also Technical specifications of the diagnostics module DM10 (Page 235) LEDs of the DM10 diagnostics module (Page 177) 46 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Description 3.5 Description of the components 3.5.11.2 Measuring socket assignment The process data acquisition system (PADU8) is used for the diagnosis of analog and digital converter signals. The process data acquisition system is designed as an optional component. If the PADU8 is not included, the signals can be read out with the aid of an oscilloscope, for example, at measuring sockets. Figure 3-9 Printed circuit board of the diagnostics module Measuring sockets Signal Measuring sockets Signal X20/X28 or X29 AO_0 X26/X28 or X29 AO_6 X21/X28 or X29 AO_1 X27/X28 or X29 AO_7 X22/X28 or X29 AO_2 X14/X18 or X19 DO_4 X23/X28 or X29 AO_3 X15/X18 or X19 DO_5 X24/X28 or X29 AO_4 X16/X18 or X19 DO_6 X25/X28 or X29 AO_5 X17/X18 or X19 DO_7 3.5.11.3 Interface description of the connectors The individual module elements of the DM10 diagnosis module supply several interfaces. The interfaces are occupied by the following connectors: X231 X232 X1 X5 X31 X32 X33 X34 PSA connection PSA connection PADU8 connection (option G66) PADU8 connection (option G66) Closed-loop control interface Closed-loop control interface Binary process diagnosis with PADU8 (option G66) Closed-loop control interface SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 47 Description 3.5 Description of the components X35 X36 Closed-loop control interface Closed-loop control interface Connector assignment Table 3-1 Connector -X231 Pin Signal type Signal designa Signal direction tion Measuring sockets Control signals closed-loop control PADU8 (option G66) 1 1M24 2 DO_3 Binary signal 3 -X32:7 3 DO_2 Binary signal 2 -X32:5 4 1M24 -X32:6 5 1M24 -X32:4 6 DO_1 Binary signal 1 -X32:3 7 DO_0 Binary signal 0 -X32:1 8 1M24 -X32:2 9 1M24 -X31:8 -X1:8 10 AO_3 Analog signal 3 -X23 -X31:7 -X1:7 11 AO_2 Analog signal 2 -X22 -X31:5 -X1:5 12 1M24 -X31:6 -X1:6 13 1M24 -X31:4 -X1:4 14 AO_1 Analog signal 1 -X21 -X31:3 -X1:3 15 AO_0 Analog signal 0 -X20 -X31:1 -X1:1 16 1M24 -X31:2 -X1:2 -X32:8 Signals DO_0 to DO_3 of connector -X32 are identical to signals DI_0 to DI_3 of connector -X231, which are supplied from the PSA. An LED signals the logic state of the respective signals. These signals are not wired to the PADU8 interface. The eight digital outputs of the PSA are used internally and are therefore preassigned, so not configurable. The eight analog outputs of the PSA are freely parameterizable and can be used for commissioning and service purposes with the aid of the starter. Follow the description in the Sinamics List Manual to parameterize the system. Note Preassignment of the analog outputs of the PSA If the converter has optional door indicating devices, analog outputs AO_0 to AO_3 of the PSA are preassigned. 48 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Description 3.5 Description of the components Table 3-2 Connector -X232 Pin Signal type Signal designa Signal direction tion Measuring sockets Control signals closed-loop control PADU8 (option G66) 1 1M24 2 DO_7 Binary signal 7 3 DO_6 Binary signal 6 4 1M24 5 1M24 6 DO_5 Binary signal 5 -X15 -X5:11 7 DO_4 Binary signal 4 -X14 -X5:9 8 1M24 9 1M24 10 AO_7 Analog signal 7 11 AO_6 Analog signal 6 12 1M24 13 1M24 14 AO_5 Analog signal 5 -X25 -X1:11 15 AO_4 Analog signal 4 -X24 -X1:9 16 1M24 -X18 -X5:16 -X17 -X5:15 -X16 -X5:13 -X19 -X5:14 -X5:12 -X5:10 -X28 -X1:16 -X27 -X1:15 -X26 -X1:13 -X29 -X1:14 -X1:12 -X1:10 The eight digital outputs of the PSA are used internally and are therefore preassigned, so not configurable. The eight analog outputs of the PSA are freely parameterizable and can be used for commissioning and service purposes with the aid of the starter. Follow the description in the Sinamics List Manual to parameterize the system. Table 3-3 Connectors -X1 and -X31 Plugs Pin Signal type Signal designation -X1 and -X31 1 AO_0 Analog signal 0 -X1 and -X31 2 1M24 -X1 and -X31 3 AO_1 -X1 and -X31 4 1M24 -X1 and -X31 5 AO_2 -X1 and -X31 6 1M24 -X1 and -X31 7 AO_3 -X1 and -X31 8 1M24 -X1 9 AO_4 -X1 10 1M24 -X1 11 AO_5 -X1 12 1M24 -X1 13 AO_6 -X1 14 1M24 -X1 15 AO_7 -X1 16 1M24 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Analog signal 1 Analog signal 2 Analog signal 3 Analog signal 4 Analog signal 5 Analog signal 6 Analog signal 7 49 Description 3.5 Description of the components Table 3-4 Connector -X32 Pin Signal type Signal designation 1 DO_0* Binary signal 0 2 1M24 3 DO_1* 4 1M24 5 DO_2* 6 1M24 7 DO_3* 8 1M24 Binary signal 1 Binary signal 2 Binary signal 3 Signals DO_0 to DO_3 of connector -X32 are identical to signals DI_0 to DI_3 of connector -X231, which are supplied from the PSA. An LED signals the logic state of the respective signals. These signals are not wired to the PADU8 interface. Table 3-5 Connector -X33 Pin Signal type Signal designation Signal direction PADU8 (option G66) 1 DO_EO External binary signal 0 -X5:1 2 1M24 3 DO_E1 External binary signal 1 4 1M24 5 DO_E2 6 1M24 7 DO_E3 8 1M24 -X5:2 -X5:3 -X5:4 External binary signal 2 External binary signal 3 -X5:5 -X5:6 -X5:7 -X5:8 Four binary plant signals can be wired via connector -X33 for diagnosis with the PADU8. Table 3-6 Connector -X34 Pin Signal type Signal designation 1 1P24 +24 V 2 1M24 Ground 3 1M24 Ground 4 1N24 -24 V The internal supply voltlage is connected at connector -X34, from which the 1P15 and 1N15 supply voltages are generated for the analog amplifiers. At the same time, comparators monitor these two voltages for undervoltage. Table 3-7 Connector -X35 Pin Signal type Signal designation 1 2P24_1 External +24 V 2 2P24_2 Signal monitoring input for external +24 V 50 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Description 3.5 Description of the components Pin Signal type Signal designation 3 2M24 Ground 4 2M24 Ground 5 HK_1 Auxiliary contact: A1 6 HK_2 Auxiliary contact: A2 The external supply voltage 2P24 is connected at connector -X35. This voltage, supplied from a 10 A power supply unit, is selectively distributed via several single-pole miniature circuit-breakers. Their auxiliary contacts can be wired to HK_1 and HK_2. In addition, a further external power supply 2P24_2 can be monitored for undervoltage. Table 3-8 Connector -X36 Pin Signal type Signal designation 1 PS_OK Power Supply OK 2 2M24 Ground Connector -X36 informs the closed-loop control system of the monitoring state. 3.5.11.4 Signal processing Tasks of the operational amplifier The Power Stack Adapter returns analog signals within a range of values from 0 V to 10 V to the DM10 diagnosis module. Because of this fixed value range, signed signals such as the actual speed value cannot be represented. Eight AD8674 operational amplifiers boost the voltage signal (reduced by 5 V) by a factor of 2. As a result of this signal handling, it is also possible to represent signals in a range of values from -10 V to +10 V. In order to be able to perform signal handling with great accuracy, the operational amplifiers must satisfy the following criteria: Low noise: 2.8 nV/Hz Large bandwidth: 10 MHz Low quiescent input curent: max. 12 nA Low offset voltage: max. 75 V The signals are relayed to the following interfaces: For diagnosis to the process data acquisition system (option G66). For alternative diagnosis with the aid of indicating instruments (option K21/K22). Via additional isolation amplifiers to the control station / I&C. For simplified diagnosis with an oscilloscope to measuring sockets X20 to X27. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 51 Description 3.5 Description of the components Tasks of reference module AD586LR The reference module installed on the DM10 diagnosis module supplies the reference voltage for voltage subtraction of the eight analog signals. The reference voltage of 5 V is subtracted from the input signal in the value range from 0 V to 10 V. The voltage supplied by the reference element must meet demanding requirements in terms of signal accuracy. The reference element must satisfy the following signal accuracy criteria: High linearity Low drift Voltage deviation of max. 5 mV The signal accuracy of the AD586LR reference element is within the permitted tolerance range with a deviation tolerance of 2.5 mV. 3.5.11.5 Voltage monitoring Tasks of the comparators The internal voltages are connected via connector -X34 and the external voltages via connector -X35. These voltages are required for supplying the diagnosis module. At the same time these voltages are monitored for undervoltage, and the logic signal state is visualized by one LED in each case. If all the voltages being checked are within the standard range, another LED (H23) signals "Power Supply OK". Connector -X36 carries the information about the status of the power supply to the closed-loop control system. If the status of the power supply is reported to the closed-loop control system as "Power Supply Not OK", the control system intervenes and shuts down the drive in a controlled manner in order to prevent damage to the drive. Switching thresholds for voltage monitoring Input voltage Signal type Connecting terminal Switching threshold 1 signal Switching threshold 0 signal +24 VDC 1P24 -X34:1 19.47 V - 19.62 V 18.98 V - 19.12 V -24 VDC 1N24 -X34:2 19.47 V - 19.62 V 18.98 V - 19.12 V +24 VDC 2P24_1 -X35:1 19.47 V - 19.62 V 18.98 V - 19.12 V +24 VDC 2P24_2 -X35:2 19.47 V - 19.62 V 18.98 V - 19.12 V 52 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Description 3.5 Description of the components 3.5.12 Re-cooling unit 3.5.12.1 Re-cooling unit requirements The re-cooling unit must comply with the following requirements: The raw water to be supplied by the plant flows through the heat exchanger that cools the deionized water. To limit the volume of the deionized water, a re-cooling unit with a dualcircuit system is required. Limit the deionized water circuit to the re-cooling unit and the drive. The design of the re-cooling unit is part of the system integration. This affects, in particular, deviations from the required environmental conditions, such as aggressive cooling water. Use heat exchanger plates made of titanium for aggressive cooling water, such as sea water or high chloride content. If necessary, also consider an increased corrosion for the design. In the variant as water-air re-cooling unit, the heat loss is dissipated to the ambient air using a separate installed heat exchanger. If you expect air temperatures below 0 C, you must install a water-glycol intermediate circuit. Glycol is not permitted in the ionized-water circuit. The measuring units and the control of the electrical equipment are evaluated in the recooling unit. The supplier calibrates the measuring units in accordance with the order specifications. Any failure of the re-cooling unit causes the immediate shutdown of the drive. If the recooling unit is provided by the system integrator, take this into consideration for the configuring. Use two redundant circulating pumps. No interruption of the flow is permitted. The only exception is a pump shutdown. The shutdown time must not exceed three seconds. Provide an overpressure valve in the raw water discharge of the heat exchanger. To keep the temperature of the ionized water constant within specified limits and to prevent condensation, on request, a control valve (tree-way valve) can be installed as bypass. Because the valve is controlled depending on the temperature of the deionized water, up to approx. 100% of the raw water can be conveyed past the heat exchanger. Acquire the temperature of the raw water with a sensor and evaluate the data. To reduce the raw water consumption, the flow quantity can be reduced. A reduction, however, is possible only when the raw water does not contain any suspended matter that could accumulate in the heat exchanger for a slower flow speed. Procure timely any consumables and spare parts from the supplier of the re-cooling unit. 3.5.12.2 Operating principle of the re-cooling unit The re-cooling unit dissipates the heat loss from the drive. The deionized water in the internal water circuit absorbs the heat of the drive power unit which is to be dissipated, and is pumped to the heat exchanger by a maintenance-free circulating pump. The warm deionized water is cooled by the external raw water circuit and pumped back to the drive. Two pipes are installed in the drive. The cold water of the re-cooling unit flows in one of the pipes, and is heated by the losses and flows back to the re-cooling unit through the other pipe. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 53 Description 3.5 Description of the components 3.5.12.3 The internal deionized water circuit The internal water circuit is filled with deionized water (deionized, fully-desalinated water). The conductivity of the cooling water must be 1 S/cm in operation. NOTICE 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. Deionized water requirements Deionized water requirements Table 3-9 Deionized water requirements Value Conductivity during filling < 10 S/cm Evaporation residue < 20 mg/l pH value 5 to 9 Content of metals in the hydrogen sulfide group (lead, antimony, tin, bismuth, arsenic, copper, cadmium) Not detectable Content of metals from the ammonium sulfide group (iron, cobalt, nickel, chrome, manganese) Content of sulfur chloride and nitrogen compounds Content of oxidizable, organic substances 3.5.13 Max. a quantity equivalent to the usage of 30 mg/l potassium per manganate KMnO4 Customer terminal strips The default setting and interfaces of the customer terminal strips can be found in the circuit manual. For information about the position of the customer terminal strips within the cabinet, see the layout diagrams. See also Terminal assignments (Page 236) 54 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Description 3.6 Description of options 3.6 Description of options 3.6.1 NAMUR terminal strip (option B00) The NAMUR command source is a terminal strip that is equipped with isolation amplifiers and relays and is located upstream of Terminal Modules TM31 and TM15. Note The inputs and outputs assigned to the terminals fulfill PELV (Protective extra-low voltage) requirements. The NAMUR terminal strip fulfills the requirements and guidelines of the standards association for measurement and control technology in the chemical industry (NAMUR recommendation NE37). On the NAMUR terminal strip, certain device functions are assigned to fixed terminals. The fixed assignment between drive signals and the NAMUR terminals represents your standardized control logic in the converter and fulfills the requirements for protective separation. To monitor the temperature of explosion-protected motors, options for PTC tripping devices with PTB approval and PT100 for use in hazardous areas are available. See also Terminal assignment of the NAMUR terminal strip (option B00) (Page 237) 3.6.2 Auxiliary voltage supply 3 AC 200 V 50 Hz (option C30) The auxiliary voltage of 3AC 200 V 50 Hz provided is adapted to the required auxiliary voltage of 3AC 400 V. The following components require a 3 3 AC auxiliary voltage supply: Fan Open-loop and closed-loop control Protection and monitoring equipment DC link precharging Re-cooling unit pumps Refer to the drive technical data for auxiliary power supply current rating. The terminal assignment is provided in the circuit diagram of the drive. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 55 Description 3.6 Description of options 3.6.3 Suitable for marine use with individual certificate from Lloyds Register (LR) (option E21) The design and implementation of the drive corresponds to the requirements of the Lloyds Register classification society. This option contains the following equipment/features: Strengthened mechanical cabinet design Handrail below the operator panel Mechanical cabinet door locking Cabinet design in an IP44 degree of protection Anti-condensation heating The drive can be welded to the ship's hull structure. See also Anti-condensation heating (option L55) (Page 66) 3.6.4 Isolation amplifiers for optional analog inputs (option E86) This option provides two isolation amplifiers if an additional TM31 Terminal Module is provided as an extension of the customer interface and the TM31 analog inputs are to be used with a higher-level control level for communication purposes. Multifunction interface converters with the following adjustment range are used: 0 V to 10 V 0 mA to 20 mA 4 mA to 20 mA The range must be set on the isolating transformer. 3.6.5 Isolation amplifiers for optional analog outputs (option E87) This option provides two isolation amplifiers if an additional TM31 Terminal Module is provided as an extension of the customer interface and the TM31 analog inputs are to be used with a higher-level control level for communication purposes. Multifunction interface converters with the following adjustment range are used: 0 V to 10 V 0 mA to 20 mA 4 mA to 20 mA The range must be set on the isolating transformer. 56 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Description 3.6 Description of options 3.6.6 Can Bus interface (option G20) The standard version of the drive is equipped with a PROFIBUS interface (slave). Communication Boards CBC10 and CBE20 are used to link the drive to the CANopen bus system. For more information about communication modules, see document "Supplementary component descriptions". 3.6.7 Modbus RTU Slave interface (option G22) Using the Anybus X-Gateway communication module, the converter can be connected to the Modbus RTU third-party bus system. The standard version of the drive is equipped with a PROFIBUS interface (slave). The "AnybusX-Gateway" supplied by HMS Industrial Networks is used to link the drive to the third-party bus system. The X gateway is connected to the CU320 Control Unit using a PROFIBUS cable. The option is supplied with a null modem cable for configuring the X gateway. The gateway is preconfigured to 20 bytes of I/O data. The data size is changed via the configuration interface from a PG/PC (standard PC tool "Windows Hyper Terminal"). Use the "NetTool" supplied by HMS Industrial Networks to configure PROFIBUS. The NetTool is not included in the scope of supply. 3.6.8 1x temperature sensor evaluation unit TM150 (option G51) This option comprises a temperature sensor evaluation unit TM150. Terminal Module TM150 is used for sensing and evaluating several temperature sensors. Terminal Module TM150 is designed to connect a maximum of 12 temperature sensors. For more information, see document "Supplementary component descriptions". 3.6.9 Additional Terminal Module TM31 (option G61) One TM31 and two TM15 Terminal Modules are already part of each standard variant of the drive. The Terminal Modules are used for the following functions: Inclusion of warning and fault messages and control signals Communication with a higher-level control level. If the number of signals to be monitored is insufficient, the interface can be extended to include an additional Terminal Module. Additional digital inputs and outputs and two analog inputs and outputs are available with the TM31. The inputs and outputs are used, for example, for fetching temperatures. The TM31 Terminal Module provides the following inputs and outputs: 8 digital inputs 4 bidirectional digital inputs and outputs SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 57 Description 3.6 Description of options 2 relay outputs with changeover contact 2 analog inputs 2 analog outputs 1 temperature sensor input (KTY84-130/PTC) Note The second TM31 must be connected at the plant site. The default setting of the inputs/outputs is not provided by the factory and must be undertaken according to the requirements of the respective plant during commissioning. When the analog inputs and outputs on the optional TM31 are used for communicating with the control level, additional isolating transformers are available (optional). 3.6.10 Additional Terminal Module TM15 (option G63) One TM31 and two TM15 Terminal Modules are already part of each standard variant of the drive. The Terminal Modules are used for the following functions: Inclusion of warning and fault messages and control signals Communication with a higher-level control level. With the optional additional Terminal Module TM15, you can also expand the number of digital inputs and outputs. The expansion makes sense for the following applications: Reading in and processing external signals in addition to the existing terminal strip available as standard. Controlling external components. The Terminal Module TM15 comprises the following elements: 24 bidirectional digital inputs and outputs (isolation in three groups of eight channels). 24 green status LEDs for indicating the logical signal status of the relevant terminal 3.6.11 PADU8 diagnosis module (option G66) The PADU8 diagnosis module can read up to eight analog and eight digital signals from the control and monitoring module in the power unit. The PADU8 makes these signals available for further processing for diagnostic purposes. The typical acquisition cycle of all channels in parallel is 1 ms which allows rapid signal characteristics to be acquired and diagnosed simultaneously. The acquired values are transferred to an evaluation system (e.g. notebook) either via fiber-optic conductors or via an RJ11 socket. All the output data is available on both the fiber optic cable output and the RJ11 socket simultaneously. This means that measurements can be taken on the RJ11 socket without disrupting data transfer via the fiber optic cable. With this option, a PADU8 diagnosis module is integrated in each control section. 58 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Description 3.6 Description of options 3.6.12 Indicator lamps in the cabinet door (option K20) This option provides five lamps in the cabinet door of the control section that indicate the operating status of the drive. Fault (red) Alarm (yellow) Operating (green) Ready for operation (white) Operation in local mode (white) 3.6.13 Display instruments in the cabinet door for voltage, current, speed, and output plus indicator lamps (option K21) Analog display instruments that display process variables as % are integrated in the cabinet door: Motor current (0 to +120%) Motor speed (-120% ... 0 ... +120%) Calculated motor power (0 to +120%) Motor voltage (0 to +120%). Note Option K21 contains option K20. 3.6.14 Sensor Module SMC30 (option K50) The SMC30 (Sensor Module Cabinet-Mounted 30) evaluates motor encoder signals. The sensor module transfers the speed and actual position value to the Control Unit via the internal DRIVE-CLiQ communication interface. Note If an encoder fails, the mode can be switched over to "encoderless". For more information, please refer to "Supplementary component descriptions" on the converter CD. See also Connecting the encoder to the SMC30 Sensor Module (Page 106) SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 59 Description 3.6 Description of options 3.6.15 dv/dt filter (option L10) The drive generates pulses at the drive output which have a negative impact on the motor insulation. The dv/dt filter is used to limit the voltage gradient to max. 1 kV/s. At the same time, the dv/dt filter is used to limit the capacitive recharging currents of the motor cables, and therefore protects the motor insulation system. The dv/dt filter is integrated in the power unit. Drive R1,R2,R3 6 dv/dt filter resistance L1, L2,L3 20 H dv/dt filter reactor C1,C2,C3 1 F dv/dt filter capacitor M Center of the drive N Center point of the dv/dt filter Figure 3-10 60 Motor Circuit diagram option L10 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Description 3.6 Description of options Connecting the motor to the dv/dt filter Figure 3-11 Connecting the motor to the dv/dt filter Restrictions when using the dv/dt filter The drive may be operated only with following maximum currents: - 4 kA drive: 1680 A (without filter 1750 A) - 5 kA drive: 1780 A (without filter 1850 A) The pulse frequency of the drive must not exceed 200 Hz. The permissible output frequency of the drive must not exceed 100 Hz. The following line length between the filter output and the motor is permitted with shielded cables (cable cross-section 185 mm2): - 200 m when six parallel cables are used - 400 m when three parallel cables are used The re-cooling unit requires 10 liter more flow SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 61 Description 3.6 Description of options 3.6.16 dv/dt filter (option L11) The input filter is used to limit the voltage gradient to max. 1 kV/s. At the same time, the input filter is used to limit the capacitive recharging currents of the line cables and so protects the transformer insulation system. The input filter is integrated into the power unit. Transformer R1,R2,R3 6 Filter resistor L1,L2,L3 20 H Filter reactor C1,C2,C3 1 F Filter capacitor M Center of the drive N Center point of the dv/dt filter Figure 3-12 Drive Circuit diagram option L11 Usage restrictions for the input filter The drive may be operated only with following maximum currents: - 4 kA drive: 1680 A (without filter 1770 A) - 5 kA drive: 1780 A (without filter 1870 A) The following line length between the filter output and the transformer is permitted with shielded cables (cable cross-section 185 mm2): - 200 m when six parallel cables are used - 400 m when three parallel cables are used The re-cooling unit requires 10 liter more flow 62 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Description 3.6 Description of options 3.6.17 Automatic restart function (option L32) When the automatic restart function (option L32) is implemented, the drive is switched on again automatically once the power has been restored after a power failure (regardless of how long the power failure lasted). Alarms are acknowledged automatically and the drive is restarted. Voltage Sensing Module (VSM) With the automatic restart option, a Voltage Sensing Module VSM10 is integrated in the drive. The VSM10 acquires the actual voltage values at the medium-voltage level upstream of the circuit-breaker. When the medium voltage is restored after a power failure, this is detected by the open-loop/ closed-loop controllers via voltage converters when the input-side circuit-breaker has dropped out. The voltage converters should be located at the medium-voltage level upstream of the circuit-breaker. For safety reasons, a time limit between the power failure and the maximum permissible power restoration time is incorporated to ensure that the drive does not restart in an uncontrolled manner. As a further warning, an acoustic signal is output when the drive restarts. You can find further information on the Voltage Sensing Module (VSM10) in Section "Description of the Components". Prerequisites To switch in the drive via the optional automatic restart function, the following general conditions must be fulfilled: The auxiliary supplies must not fail. The power supply for the fans, coolant pumps, and the open-loop/closed-loop controllers must be maintained. If the main infeed fails, the pulse block is initiated. The DC link is supported for a short time using the precharge. Starting the drive from standstill This function is suitable for drives with small inertia loads and load torques where the drive can be brought to a standstill within seconds, such as pump drives with water gauges. Starting the drive with the flying restart function This function can also be activated as follows: The function is suitable for drives with high inertia loads (e.g. fan drives). This function can be used to switch the drive to the motor that is still rotating. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 63 Description 3.6 Description of options Failure of the auxiliary supply If the main infeed fails, the following possibilities are available: The input-side circuit-breaker is still closed. When the medium-voltage supply system has been restored, the DC-link voltage increases. This increase is detected by the closed-loop and open-loop controllers. When a threshold value is exceeded, operation is resumed. The input-side circuit-breaker has tripped. After a fixed, definable time, the circuit-breaker receives an "ON" command. The system then checks the DC-link voltage. If the DC-link voltage continues to decrease, the drive is switched off. If the DC-link voltage increases, operation is resumed when a threshold value is exceeded. Note Restriction when the drive is operated via the AOP in LOCAL mode The automatic restart function cannot be used in conjunction with the AOP30 in LOCAL mode. When the drive is operated in LOCAL mode, the AOP30 cancels the "ON" command to the circuit-breaker if fault OFF1, OFF2, or OFF3 occurs. 3.6.18 Line-side grounding switch (option L48) When the make-proof grounding switch is closed, this option allows motor-driven make-proof grounding switches that ground the line-side input voltage to be controlled automatically. The motor-driven make-proof grounding switches are installed in an additional cabinet. For safety reasons, the drive controller prevents the make-proof grounding switches from being switched when voltage is still present. Activation is integrated in the protection and monitoring sequence of the drive. The make-proof grounding switches are closed automatically when the standard make-proof grounding switch of the DC link is closed. 3.6.19 Motor-side grounding switch (option L49) Under the following circumstances, operating modes can occur for which there is the danger that the motor returns power to the drive: Operating mode / variant of the load machine, e.g. drive group with gas turbine Type of drive machine, e.g. permanently excited motor resulting in hazardous voltages. When the make-proof grounding switch is closed, this option allows motor-driven make-proof grounding switches that ground the motor-side output voltage to be controlled automatically. The motor-driven make-proof grounding switches are installed in an additional cabinet. 64 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Description 3.6 Description of options For safety reasons, the drive controller prevents the make-proof grounding switches from being switched when voltage is still present. Activation is integrated in the protection and monitoring sequence of the drive. 3.6.20 Cabinet illumination and service socket in closed-loop control unit (option L50) One universal light with service socket is installed in each cabinet element for the trigger and control section. The universal light and the power socket are supplied externally with power and must be fused with max. 16 A. The cabinet illumination can be switched on manually or automatically by means of an integrated motion detector (default setting). If the light is switched on by the motion detector, it stays on for three minutes. The mode is selected via the switch on the light. The terminal assignment is provided in the circuit diagram of the drive. 3.6.21 Disconnector at the drive output (option L51) With this option, a motor-operated isolator is integrated at the drive output. If manual isolation between the drive output and drive motor is required for protection and safety reasons, this can be achieved by means of the motor-operated isolator. 3.6.22 Circuit breaker at the drive output (option L52) With this option, a circuit-breaker is integrated at the drive output. If isolation between the drive output and drive motor is required for protection and safety reasons, this can be achieved by means of the circuit-breaker. The circuit-breaker is controlled from the drive controller. When an ON command is issued, the output-side circuit-breaker is activated along with the auxiliary equipment. When an OFF command is issued, the circuit-breaker is deactivated. 3.6.23 Uninterruptible power supply (UPS) (option L53) The uninterruptible power supply (UPS) ensures that the control system continues to run because the line voltage is protected. The following conditions must be met in order that the drive can continue to operate: The DC-link voltage does not undershoot the Ud min limit The medium-voltage switch does not switch off because of undervoltage. If kinetic buffering is activated, drives with large moments of inertia can bridge voltage brownouts or short power failures. The kinetic buffering supports the DC-link voltage. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 65 Description 3.6 Description of options 3.6.24 Anti-condensation heating (option L55) The anti-condensation heating is used at low ambient temperatures and high levels of humidity to prevent condensation from forming. The heating is controlled via a thermostat. The number of anti-condensation heaters is set in accordance with the number of cabinet panels. The converter monitors and signals if the external supply for the anti-condensation heating fails. See also Safety instructions for maintenance (Page 183) 3.6.25 EMERGENCY STOP Category 1 (option L60) Emergency Off, stop category1 (24 VDC) for controlled stop according to IEC60204. In the standard version, Emergency Off stop category 0 is set for an uncontrolled stop. It also has a function for disconnecting the drive from the power supply via the circuit-breaker. The motor coasts down. The Emergency Off, stop category 1 function includes rapid stopping of the drive using a deceleration ramp to be parameterized by the user. Voltage is then disconnected from the drive as described for Emergency Off, stop category 0. The EMERGENCY OFF button with protective collar is installed in the drive cabinet door. WARNING Danger from auxiliary voltages that are connected When you press the EMERGENCY STOP button, the motor is stopped either uncontrolled or controlled depending on the selected category 0 or 1, and the drive blocks the inverter, in line with IEC60204-1 (VDE0113). Auxiliary voltages such as those for separately-driven fans or anti-condensation heating are still present. Certain areas within the drive also remain under voltage, e.g. the control function or auxiliaries. When touching these auxiliary voltages, this can result in death or serious physical injury. Ensure that the EMERGENCY OFF button is integrated in the safety system for the whole machine so that all the voltages are completely disconnected. For this purpose, an NC contact is installed at terminals =.LA-X51:1A or 1C and =.LA-X51:2A or 2C. 66 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Description 3.6 Description of options 3.6.26 Braking Module (option L72) This option uses a Braking Module with connected braking resistor to permit braking operation. The structure of the Braking Module is similar to that for a phase of the Motor Module. The braking resistor is not included in the scope of supply but is available as option Y73. An external load resistor is provided as the braking resistor. Braking power Table 3-10 Braking power of the Braking Module with external braking resistor Converter Required braking output volt resistance ( 10%) age 3.3 kV 1) 3.2 Braking resistance supply voltage Braking power Brak Braking power Brak ing Module ing Module P20 5.8 kV 4000 kW 1) PDB 4000 kW Values can be higher for brief periods (in the range of seconds). Note The above data is valid for maximum continuous output of the Braking Module. 3.6.27 Safety locking system (option M10) The safety locking system is based on the key transfer system developed by Castell. It is a supplementary mechanism to the electromechanical door locking system integrated as standard. The medium-voltage breaker must be opened before access can be gained to the coded key of the key exchange unit. The opened medium-voltage breaker releases the key to the key exchange unit. This key enables the access to the keys for the cabinet doors of the power unit. This key interlocking system ensures that the converter is disconnected from the medium-voltage supply and that no cabinet components are connected to medium voltage. As long as the cabinet doors are not closed again and the keys to the power-unit cabinet are not inserted back in the key exchange unit, the key for the medium-voltage breaker will not be released. The medium-voltage breaker cannot be switched on again. See also Secure locking system (option M10) (Page 191) 3.6.28 Power cable connection at the drive input from above (option M13) You can introduce the line-side power cable into the cabinet from the top. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 67 Description 3.6 Description of options 3.6.29 Signal and control cable (max. 2.5 mm) (option M32) Signal and control cables are connected directly to the terminals on Terminal Module TM31 or TM15 as standard. The maximum connectable cross-section for these cables to the TM31 and TM15 Terminal Modules is limited to 1.5 mm2. With option M32, you can connect signal and control cables with connection cross-sections of up to 2.5 mm2 to a terminal strip via cage clamp terminals. 3.6.30 IP54 degree of protection (option M54) This option increases the degree of protection of the drive from IP43 to IP54. 3.6.31 Redundant fan in the power unit (option M61) To increase the plant availability, the drive can be fitted with an additional, redundant fan. If a fan in the drive cabinet fails, this is detected immediately by the differential pressure monitor in the cabinet. The redundant fan is switched in by the drive controller without this causing the drive and, in turn, the drive system to fail. This prevents production failures or interruptions. The replacement of the defective fan can be postponed to the next planned stoppage. 3.6.32 Suitability for marine use (option M66) The converter design corresponds to the requirements of the following classification societies. Lloyds Register American Bureau of Shipping Germanischer Lloyd Bureau Veritas Det Norske Veritas Chinese Classification Society The converter has the following supplementary equipment: Salt water resistant paint Strengthened mechanical cabinet design Handrail below the operator panel Mechanical cabinet door locking IP44 degree of protection Anti-condensation heating The converter can be welded to the ship's hull plate 68 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Description 3.6 Description of options 3.6.33 Controlled outgoing circuit for auxiliary equipment 400 V 3 AC (option N30) This option includes a controlled outgoing feeder for external auxiliaries (3 AC 400 V, max. 4 KW). The controlled outgoing feeder is protected by a circuit breaker. The circuit breaker setting range is cos phi = 0.8 (7 A up to 10 A). The option can be used to operate external fans on motors and pumps and oil supply units. The "ON" command at the drive closes the contactor. The "OFF" command opens the contactor. Externally provide the necessary drive power supply. The terminal assignment is provided in the circuit diagram of the drive. 3.6.34 Sine-wave filter (option Y15) This option allows line motors or motors with insulation systems that are not compatible with drives to be operated with speed control. The sine-wave filter supplies the motors with virtually sinusoidal motor currents and voltages, which means that line motors can be used. Standard cables (without EMC shielding) can also be used between the sine-wave filter and the motor. When sine-wave filters are used, the voltage harmonic distortion at an output frequency of 50 Hz is less than 5%. When the sine-wave filter is used, refer to the performance data (see the technical specifications). Only work machines with square load characteristic curve (centrifugal pumps and water turbines) can be operated. Field-weakening operation is not permitted. Possible rated output frequencies are limited to a range of 30 Hz to max. 66 Hz. The frequency setting range is 1:10. Table 3-11 Max. permissible cable lengths Permissible maximum cable lengths (shielded and unshielded cables) Without sine-wave filter With sine-wave filter 100 m 1000 m SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 69 Description 3.6 Description of options Connecting the motor to the sine-wave filter A Basic configuration B Parallel connection C Parallel connection, two separate winding systems Figure 3-13 70 Connecting the motor to the sine-wave filter SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Preparations for use 4 Observe Chapter, "Safety instructions" when carrying out any work at the converter. See also Safety instructions (Page 19) 4.1 Requirements for installation location The cabinet units are suitable for installation in general operating areas (to DIN EN 60146-1-1 / VDE 558 T11 and DIN EN 50178 / VDE 0160 (IEC 62103), degree of contamination 2; without conducted contamination). For this reason, SINAMICS devices must be protected in such a way that they cannot be touched directly when they are being installed in general operating areas. The operating areas must be dry and free of dust. The air supplied must not contain any electrically conductive gas, vapors, or dust which could impair operation. For information about permissible ambient and installation conditions, see the "Technical data and drawings" section. 4.2 Inspections when receiving the delivery 4.2.1 Checking the delivery The components are assembled on an individual basis. When you take receipt of the delivery, please check immediately whether the scope of the delivery matches up with the accompanying documents. No claims relating to defects/items missing from the delivery will be accepted if they are submitted at a later date. Report any apparent transport damage to the delivery agent immediately. Immediately report any apparent defects/missing components to your contact partner. These Operating Instructions are part of the scope of delivery; keep them in a location where they can be easily accessed. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 71 Preparations for use 4.2 Inspections when receiving the delivery 4.2.2 Scope of delivery The scope of delivery includes the following components: Power unit, incl. closed-loop control Excitation cabinet (for synchronous motors only, can be ordered separately) Re-cooling unit (optional) This documentation relates to the complete system without the re-cooling unit. 4.2.3 Checking shock and tilt indicators The purpose of shock and tilt indicators The unit is equipped with shock and tilt indicators to monitor for damage during transit. It is essential that you check the shock and tilt indicators before commissioning the unit. WARNING Tripped shock and tilt indicators Safe operation of the device is not guaranteed if the shock or tilt indicator has tripped (responded) This can result in death, serious injury or material damage. If one of the indicators has tripped, do not perform any commissioning. Inform the Technical Support. Only specialist Siemens technicians can recommend appropriate measures. See also Service & Support (Page 229) 72 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Preparations for use 4.2 Inspections when receiving the delivery Location and display of the indicators You can find the indicators at the following locations: The tilt indicators are located in the upper third of the cabinet. If the arrow above the line is blued, the tilt indicator has tripped. The shock indicators are located at the bottom of the cabinet. If one or both arrows are black, the shock indicator has tripped. Figure 4-1 4.2.4 Example of attaching and displaying the shock and tilt indicators Checking the load handling attachments Check the load suspension devices before lifting and transporting (such as lifting lugs and eyebolts) and the lifting gear: Inspect the load suspension devices attached to the equipment for possible damage. Replace load suspension devices if they are damaged. Before use, check that the load suspension devices are correctly attached. When lifting, use only approved and undamaged lifting gear of sufficient rated capacity. Check the lifting gear prior to its use. WARNING Load suspension devices and lifting gear damaged If the load suspension devices and lifting gear are damaged or not correctly secured, the equipment may be dropped during lifting and transportation. This can result in death, serious injury or material damage. Inspect the load handling attachments and lifting gear before use. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 73 Preparations for use 4.3 Transportation 4.3 Transportation The terms are defined as follows in the following part of the instructions: "Transportation unit" refers to the unit before it has been unpacked "Cabinet" refers to the unit after it has been unpacked 4.3.1 Transport markings The packing differs depending on the transport type and size. If not otherwise contractually agreed, the packaging corresponds to the packing guidelines for International Standards for Phytosanitary Measures (ISPM). Note the symbols which appear on the packing. These have the following meanings: Top 4.3.2 Fragile material Keep dry Keep cool Center of gravity Do not use hand hook Attach here Transport requirements Persons driving cranes and fork-lift trucks must hold appropriate licenses. You must observe the specifications to avoid transport damage to the enclosure and you must maintain the permissible climatic conditions during operation in accordance with IEC 60721-3-1/2/3. Please also observe the "Technical specifications" instructions. When lifting the drive, use only approved and undamaged sling guides and spreaders of sufficient rated capacity. Check these before using them. The weight of the drive is specified on the rating plate. When lifting, refer to the information on the lifting plate or in "Technical data and drawings." Comply with the specified spreading angles. NOTICE Vibrations Significant vibration during transportation and shocks when setting down can damage the equipment. Avoid vibrations and shocks. 74 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Preparations for use 4.3 Transportation 4.3.3 Observe center of gravity WARNING Non-observance of center of gravity specifications The cabinet is heavy. The center of gravity can be in the upper half of the cabinet. The unit can tip over if you transport it incorrectly - or if you use transport equipment that is not permitted for the purpose. This can result in death, serious injury or material damage. Ensure that only trained personnel transport the device with approved transport equipment and lifting tools. Observe the center of gravity specifications. A label or stamp is attached to each transportation unit and precisely shows the center of gravity of the cabinet. Do not tilt the device or allow it to fall. The following figure shows the centers of gravity as an example: Carefully note the centers of gravity when performing any lifting or installation work. 6LGHYLHZ )URQWYLHZ Figure 4-2 4.3.4 Example illustration of centers of gravity Transport with a fork-lift truck WARNING Use of non-approved fork-lift trucks If the forks are too short, this can cause the transport unit/cabinet to tip over resulting in death, serious injury, or damage to the cabinet. The forks of the truck must protrude at the rear of the transport pallet. The floor panels of the transport units will not support a load. Only use fork-lift trucks approved for this purpose to transport the units. When the transport units are transported or moved with a fork-lift truck, the force is absorbed through the transport pallet. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 75 Preparations for use 4.3 Transportation Observe the following points for safe transport: Transport the transport unit/cabinet with the greatest care. Choose the lowest transport height possible. The pallet may not touch the ground. Always transport the cabinet in an upright position. Avoid driving over bumps. 4.3.5 Transport with a crane WARNING Improper transport If the transport unit is not properly transported with a crane, the transport unit/cabinet could fall or tip over This can result in death, serious injury or material damage. Make sure that you read the safety information about transportation and the information provided on the transport unit (e.g. center of gravity specifications). WARNING Use of inappropriate 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. WARNING Standing under suspended loads If the lifting gear or load suspension devices were to fail, the transport unit/cabinet could fall. This can result in death, serious injury or material damage. Do not stand underneath or near to a raised load. Observe the following points for safe transport: When using a crane to transport the equipment, keep to the permissible lifting capacity. Pay attention to the center of gravity position. If the cabinet center of gravity is off-center, use suitable lifting equipment, e.g. a lifting beam. If the cabinet has eye hooks, use them. In such cases, do not use any lifting rods. 4.3.6 Using lifting rods During transportation with a crane, force is absorbed by the supporting frame of the cabinet. The supporting frame remains on the unit. The device is mounted at the installation site via the supporting frame. 76 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Preparations for use 4.3 Transportation Note Transporting the option cabinet When transporting an option cabinet, the force is absorbed via the screwed-on U sections. Remove the U sections after transporting the cabinet. Note Lifting bars The lifting bars are not included in the scope of delivery. WARNING Inadequately dimensioned lifting rods Inadequately dimensioned lifting rods are liable to bend or break. The drive could drop off the crane. This can result in death, serious injury or material damage. Use suitable lifting rods for transporting. The weight of the cabinet is indicated on the rating plate. NOTICE Improper lifting If the transport unit is lifted incorrectly, this can damage the decorative trim, cabinet doors, or fans. Protect the cabinet and protruding parts against damage. Always lift the transport units with the appropriate spreading devices or hoisting tackle. 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. Figure 4-3 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Lifting bar label 77 Preparations for use 4.3 Transportation 3. Place the sling ropes on the lifting bars so they are close to the cabinet. Secure the ends of the lifting bars using the splint. Figure 4-4 Securing the lifting rods 4. To lift the transport unit, use single sling ropes or two ropes with a cross stitch. Attach the crane rope to the lifting rods so it is close to the cabinet. 5. Lift the cabinet. Avoid shifting the center of gravity or distorting or damaging the cabinet. When suspended, the cabinet must be parallel to the ground. 4.3.7 Transporting transportation units packed in boxes Transportation with the fork-lift truck WARNING Use of non-approved fork-lift trucks If the forks are too short, this can cause the transportation unit/the device to tip over resulting in death, serious injury, or damage inside the cabinet. The forks of the truck must protrude at the rear of the transportation unit. Only use forklifts approved for the purpose of transporting the devices. Transportation with the crane WARNING Standing under suspended loads 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. 78 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Preparations for use 4.4 Unpacking 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 and the crane hook. 3. Pay attention to the center of gravity imprinted on the box and the imprinted position of the ropes . 4. Carefully raise the transportation unit. Spreader beam Center of gravity Imprinted position of the rope Figure 4-5 Transporting a transportation unit (still in packaging) with a crane 4.4 Unpacking 4.4.1 Removing the packaging NOTICE Incorrect storage of unpacked devices Proper packaging ensures that the equipment is protected. Unpackaged equipment may be damaged if it is stored or out of service over a long period. Carefully observe the instructions for storage in Chapters "Storage" and "Technical data and drawings". Remove the packaging immediately prior to installation. The units are packed by the manufacturers in accordance with the order. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 79 Preparations for use 4.4 Unpacking In order not to damage open mounting parts (e.g. pipes and busbars), take the following measures when removing the foil and the load securing devices: Remove the foil and load securing devices carefully. Remove the packaging immediately prior to installation. Protect the cabinets against dust until they have been commissioned. To do this, cover the ventilation openings and keep the doors closed. Do not remove the safety instructions and center of gravity specifications from the cabinet. 4.4.2 Removing load securing devices WARNING Fixing materials can come under tensile stress If fixing materials are released suddenly during opening and people get in the way, this could result in bodily injury or death. Release the retaining straps before opening. Stay out of the way of the impact direction of the retaining straps. NOTICE Improper removal of the load securing devices The load securing device protects the cabinet from any damage. If you remove the load securing device improperly, the cabinet may sustain damage. Correctly remove the load securing device. To extract the load securing device, proceed as follows: 1. Remove the retaining straps. 2. Remove the spacers such as wooden wedges, air cushions, etc. 4.4.3 Lifting the cabinet off the transport pallet Use a crane to lower the transportation units from the transport pallets and transport them to the installation site. Observe the guidelines described in the section "Transport with a crane." 80 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Preparations for use 4.4 Unpacking 4.4.4 Opening doors in preparation for use NOTICE Incorrectly opening the doors If you incorrectly open the doors, then this can damage the locking mechanism. When opening the doors, follow the steps described. You must replace a damaged locking mechanism before commissioning, which will be charged for. Contact the service center in this regard. You can find the relevant contact person under "Service & Support". 4.4.4.1 Opening doors in preparation for use The converter is delivered in a closed state. A label showing how to open the doors in a currentfree state is located on the door. Figure 4-6 Example: Label with instructions for opening the doors Proceed as follows: 1. A screw marked with a label is located in the door. Under the screw you will find the opening for manually opening the doors. Remove the screw. Figure 4-7 Example: Cover screw for manual door interlocking 2. Insert a screwdriver into this opening. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 81 Preparations for use 4.5 Storage 3. Turn the door handle until you feel resistance. 4. Remove the screwdriver from the opening. 5. Open the doors. After opening the doors, remove the label with the instructions for safety reasons. The label is only required for opening the doors the first time. 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" See also Checking shock and tilt indicators (Page 72) 4.5 Storage 4.5.1 Emptying the drive NOTICE Unemptied cooling system The coolant can corrode the components over the long term. Coolant can also freeze at temperatures of below 0 C causing damage to the drive. Make sure that the coolant has been completely removed from the system before the device is placed in storage. If the drive is stored for a longer period of time, then close and seal all water intakes and discharge points to protect against vermin and dirt. If the drive was already connected to the cooling system and you want to store the drive away again, empty the drive completely prior to storing. To empty the drive proceed as follows: 1. Open the connection between the cabinet piping and the external piping. 2. Drain the coolant. 3. Then tighten the screws again. 4. At one of the flanges of the cabinet piping, connect oil-free compressed air or a nitrogen bottle. Use a suitable transition element. Blow out any residual water. 82 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Preparations for use 4.5 Storage NOTICE Blow-out pressure too high If the blow-out pressure used exceeds 6 bar, the piping and the heat sink can become damaged. Do not exceed the blowout pressure of 6 bar. Avoid pressure surges. 4.5.2 Storing a device If you are not going to commission the device immediately after delivery, ensure that it is stored correctly. Preconditions and preparations Store goods only in undamaged packaging. Unpack the goods if the packaging is damaged. Correctly store the goods corresponding to the type of goods. Repair any damage to the packaging before putting the equipment into storage insofar as this is necessary to ensure proper storage conditions. General instructions for storage Wherever possible, store the device in a storage room. The place of storage must satisfy the following general conditions: Select a sufficiently sized dry and horizontal place of storage that is above flood level and free of vibration (veff 0.2 mm/s). The place of storage must be well ventilated as well as free of dust and frost. - Provide protection against extreme weather conditions. - Optimum temperatures are between 10 C (50 F) to 50 C (120 F). - Room temperature should be approx. 10 C (14 F) above the outside temperature. - The temperature may not fall below 20 C (-4 F). - For lower temperatures, agree on suitable measures together with Siemens. - Relative humidity should be less than 60%. - The floor of the place of storage must be sufficiently strong. Do not exceed maximum permissible floor load levels or storage compartment load levels. - The ambient air must not contain any harmful gases. Protect the device against shocks and humidity. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 83 Preparations for use 4.5 Storage In order to ensure protection against ground moisture and water, place the equipment and crates on pallets, wooden beams or foundations. Ensure that the air circulation under the equipment is not impeded. - Place wooden spacer blocks between the covers and the device. - Do not place covers or tarpaulins completely around the equipment on the floor. NOTICE Improper storage Incorrect or excessively long storage can damage the equipment. Do not store the device outdoors. Observe the specified conditions for storing the device. Ensure that it is not stored for longer than the permissible maximum of two years. Protection against humidity If a dry storage area is not available, then take the following precautions: - Wrap the device in humidity-absorbent material. Then wrap the device in film so that it is airtight. - Place a humidity meter that can be read from outside inside the film wrapping. Observe the values provided in the technical specifications on relative humidity. Check the values regularly using the humidity meter. - Inspect the device regularly. 84 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 5 Installation 5.1 Safety instructions for assembly Observe Chapter, "Safety instructions" when carrying out any work at the converter. NOTICE Improper installation The devices can be damaged through improper installation. Install the devices as described in the following sections. Take note of the ambient temperatures stated in the technical specifications. Protect the drive against excessive stress and loading. WARNING Defective seals When working on the device, seals at the doors, roof panels as well as front, rear and side panels can be damaged. Operating the device with defective seals can result in death, serious injury or material damage. Replace the defective seals before commissioning. Observe the environmental conditions stated in the technical data. WARNING Dirt deposits during installation Dirt gets deposited in the open converter during installation work. Dirt deposits can lead to the converter no longer fulfilling the requirements for cleanliness. If the converter is operated with internal pollution, death, serious injury and material damage can result. Therefore, remove dirt deposits after installation. Then keep the doors closed. In the event of contamination from conductive dust particles (e.g. from welding work), professional cleaning will be required. Contact the service center in this regard. NOTICE Foreign bodies in the drive If, after installation and maintenance work, foreign bodies are left in the drive, this can damage it when switching on. Before switching on, check as to whether there are any foreign bodies in the drive. Remove any foreign bodies. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 85 Installation 5.2 Tools required NOTICE Installation of the re-cooling unit on its own The transmission of mechanical vibrations may, for instance, cause cracks in the piping or other mechanical damage. If the re-cooling unit is screwed to the drive this may be damaged. Install the re-cooling unit on its own, without a screw connection to the drive. 5.2 Tools required Installation of the connections requires the following tools: Wrench or socket wrench, width across the flats 10, 13, 16/17, 18/19 Allen key, size 8 Torque wrench up to 50 Nm Screwdriver, size 2 Torx T20 and T30 screwdrivers 5.3 Attaching side panels WARNING Side panels that are not attached Voltages of over 1000 V are present when this equipment is operational. If the device is operated without side panels, this can result in death or serious injury. Make sure that the side panels are installed on the left and right outer ends of the drive. A basic unit consists of two transportation units (modules). There is a side panel on the lefthand side of each transportation unit. Mount the side panels of each transportation unit to the correct side. To do so, proceed as follows: 1. Arrange the transportation units in accordance with the specifications provided in the dimension drawings. 2. Make sure that on the left-hand transportation unit the side panel is mounted on the lefthand side. 3. If the drive comprises more than two transportation units, then disassemble the side panels of the following transportation units. 4. Mount the side panel of the last transportation unit from the left to the right-hand side. 86 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Installation 5.4 Screwing the transport units together Examples of the arrangement of the side panels / Re-cooling unit Transportation unit Figure 5-1 Connecting two transportation units / ; Re-cooling unit Transportation unit Figure 5-2 5.4 ; Connecting four transportation units Screwing the transport units together NOTICE Stress 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 drive only on a level and horizontal surface. Preparatory steps 1. Ensure that access to the holes in the bottom of the cabinets is unobstructed. 2. Remove the guard covers. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 87 Installation 5.5 Connecting to the foundation Screwing cabinets together The cabinets are supplied with the following mounting hardware for the purpose of screwing them together: Hexagon nuts ISO 4032-M10-8 A2L Hexagon screws ISO 4017-M10x45-8.8-A2L Hexagon screws ISO 4017-M10x140-8.8-A Washers DIN9021-10.5-140HV-A2L Spring washer VHD 10-1.4310 Proceed as follows to screw the cabinets together: 1. Remove the canopy panel2. Align the cabinets. 3. Insert the M10 screws through the mounting holes at the upper and lower sides of the cabinet. The arrangement of the mounting holes is provided in the dimension drawing. Select a suitable screw length depending on the location. 4. Place the washers and spring washer onto the screw. 5. Screw the transport units together using the nuts with a torque of 65 Nm. 6. Attach the canopy panel. 5.5 Connecting to the foundation Preparatory steps 1. Ensure that access to the holes in the bottom of the cabinets is unobstructed. 2. Remove the guard covers. Securing the cabinet to the floor The following details are specified in the dimension drawing: Mounting holes Mounting dimensions Distance between the cabinet top and the room ceiling Holes are provided for M12 screws for securing the cabinet to the foundation. Install the transportation units in accordance with the specifications provided in the accompanying dimension drawings in "Layout diagrams and dimension drawings". 88 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Installation 5.6 Connecting cabinets 5.6 Connecting cabinets DANGER 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. Always apply all of the necessary protective measures. Always observe the five safety rules when working with the drive. 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, they must be connected to each other. A connection jumper is supplied with each cabinet. To screw several cabinets together, proceed as follows: 1. Loosen the M12 nut on the first cabinet. Remove the nut, the washer and the connection jumper . 2. Loosen the M12 nut on the second cabinet. Remove the nut and the washer. 3. Place the connection jumper on the support for the connection jumper in the cabinets to be connected. 4. Refit the washer and nut. 5. Tighten the nut (torque: 50 Nm). M12 nut; washer Connection jumper Figure 5-3 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Connecting cabinets 89 Installation 5.7 Connecting the DC bus See also Torques (Page 201) 5.7 Connecting the DC bus If several cabinets are set up as one unit, you must connect the DC bus of the individual cabinets with each other. The following mounting material is provided: Combination screws SN60736-C-M8x16-Z4-L-8.8A A pack contains 50 items per bar package. 42 are required, with the remainder serving as reserve. Hexagon screws ISO 4017-M8x20-8.8-A2L 5 items with washers are included. 90 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Installation 5.8 Connecting the interface terminals Please proceed as follows: 1. Connect the connection jumper to the DC bus . 2. Screw the connection jumper firmly in place using the supplied screws with a torque of 15 Nm. Connection jumper DC bus Figure 5-4 5.8 DC-bus connection Connecting the interface terminals Connecting the interface terminals of several cabinets If several cabinets are set up as one unit, the interface terminals of the cabinets must be connected with each other. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 91 Installation 5.9 Connecting the water circuits Depending on the design of the cabinet, sockets for connecting the interfaces are located on the left-hand side (viewed from the front), below or above. The connectors are provided at the same position on the other cabinet. 1. Insert the plug into the corresponding socket . Interface terminal Connector Figure 5-5 5.9 Example: Connecting interface terminals Connecting the water circuits CAUTION 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 Damage 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. 92 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Installation 5.10 Installing the battery of the uninterruptible power supply Connect the re-cooling unit Connect the deionized water circuit of the re-cooling unit to the deionized water piping of the drive. Refer to the associated information about the ionized-water connections in the dimension drawing. 5.10 Installing the battery of the uninterruptible power supply Prerequisites The uninterruptible power supply (UPS) is supplied without a battery. For this reason, please order a battery (article number 6SL3988-6YX00-0AA0). You can find the relevant contact person under "Service & Support". Procedure 1. The five safety rules must be observed. 2. Remove the polycarbonate cover above the uninterruptible power supply. 3. Remove the screws above and below the uninterruptible power supply. Figure 5-6 Remove the screws 4. Remove the uninterruptible power supply so that you can take off the operator panel. 5. Remove the screw securing the battery holder in place. 6. Carefully remove the battery holder. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 93 Installation 5.10 Installing the battery of the uninterruptible power supply 7. Insert the battery pack . Figure 5-7 Install battery 8. To reinstall the uninterruptible power supply, perform steps 2 to 6 in reverse order. 9. Remove the "UPS without battery pack" label from the converter. 94 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Electrical connection 6.1 6 Safety instructions for electrical connections Observe Chapter, "Safety instructions" when carrying out any work at the converter. WARNING Insufficient degree of protection as a result of inadequate sealing of the cable entry If the cable entry is not correctly sealed, it is possible that the drive no longer complies with the requirements for the specified degree of protection. If the drive is operated with an insufficient degree of protection, death, serious injury, and material damage can result. To maintain the drive's degree of protection, after connecting the cable, seal the cable entries so they are air-tight immediately. WARNING Insufficient degree of protection as a result of modifying the floor/roof panel If you make any changes to the floor panel or the roof panel in order to modify the cable entry, the changes may result in the drive no longer meeting the requirements for the degree of protection shown. If there are holes in the floor or roof panel, then animals and vermin, for example, can get into drive during operation. If the drive is operated with an insufficient degree of protection, death, serious injury, and material damage can result. To maintain the drive's degree of protection, seal the holes so they are air-tight immediately after installation. WARNING Defective seals When working on the device, seals at the doors, roof panels as well as front, rear and side panels can be damaged. Operating the device with defective seals can result in death, serious injury or material damage. Replace the defective seals before commissioning. Observe the environmental conditions stated in the technical data. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 95 Electrical connection 6.1 Safety instructions for electrical connections WARNING Short-circuits Damaged cables, or their improper routing, can cause damage to property and personal injury. Only use cables that are completely intact and not damaged. Correctly route the cables. Do not interchange input and output terminals. Make sure that a short-circuit cannot occur on the power cables due to failure of the insulation as a result of incorrect cable installation. Check the electrical connections after service work. NOTICE Using magnetizable parts The use of magnetizable parts, e.g. ferrous cable clamps, is not permitted. The use of magnetizable parts can damage the converter. Only use parts that consist of non-magnetic material. NOTICE Improper shrinking of cable terminations If you are connecting the mains and motor-side power cables, when shrinking the cable terminations, other control lines and fiber-optic cables in the surrounding cable channels can become damaged. When shrinking, ensure not to damage cables in the surrounding cable channels. NOTICE Incorrectly opening the doors If you incorrectly open the doors, then this can damage the locking mechanism. Open the doors as described in Section "Preparing for use". 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. 96 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Electrical connection 6.2 Electromagnetic compatibility Note To ensure trouble-free operation without interference or disturbances, route the power cables and signal lines separately. Interference, for example, will result in the device not behaving as expected. When connecting and routing power and signal cables, observe the instructions contained in the "Electromagnetic compatibility" section. See also Electromagnetic compatibility (Page 97) 6.2 Electromagnetic compatibility The following fundamental information and guidelines facilitate compliance with the EMC directives. Note We recommend that EMC is planned for the entire plant. Cabinet installation Connect painted or anodized metal components using contact washers or remove the insulating layer. Use unpainted, de-oiled mounting plates. Establish a central connection between ground and the protective conductor system (PE protective conductor). Cable installation Cables that are subject to or sensitive to interference should be laid as far apart from each other as possible. The distance between the electric power cable and signal cable should be > 20 cm. The converter-specific information applies to power cables. You can find further information on power cables under "Connecting power cables". When the cables are routed close to ground potential, the immunity to interference is increased. For this reason, you are advised to lay these cables along edges and at ground potential. Ground the reserve cores on at least one end. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 97 Electrical connection 6.2 Electromagnetic compatibility In order to avoid additional locations where interference can be coupled in, long cables should be shortened or routed where there is little interference. If conductors or cables conduct signals of different classes, then the conductors and cables must cross at a right angle. This especially involves sensitive and noisy signals. - Class 1: Unshielded cables for 60 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. In other words, cable shields must not simultaneously act as neutral or PE conductors. Apply the cable shield so that it covers the greatest possible surface area. Use ground clamps, ground terminals or ground screw connections. Avoid extending the cable shield to the grounding point using a wire. This reduces the shield effectiveness by up to 90%. 98 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Electrical connection 6.2 Electromagnetic compatibility 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. Shield busbar Shielded cable Mounting clip Figure 6-1 Shield connection using a clip NOTICE Damaged or incorrectly mounted cable shielding Incorrect connection or damaging of the cable shield can impair the function of the system. Handle the cable shield carefully. Ensure that the cable shield is correctly connected. Bridge shield gaps (at terminals, circuit-breakers, contactors, etc.) with minimum impedance and through the largest possible surface area. Shield busbars Cables Terminals Figure 6-2 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Bridging shield gaps 99 Electrical connection 6.3 Potential concept 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 mm). 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 operating coils for contactors and relays in the converter. In order to reduce noise/interference entering or exiting via the cable, filter auxiliary voltages in the control cabinet. 6.3 Potential concept A noise-free connection between the internal and external supply voltage can be achieved by connecting the 0 V potentials to each other and grounding them. This also eliminates the need for the control circuit insulation monitor required by DIN EN 60204-1. 3 1 3 0 0 ,QWHUQDO ORDGV Figure 6-3 6.4 ([WHUQDO ORDGV Potential concept Electrical requirements Table 6-1 Dimensioning cables Object Length Cable length (motor side) 100 m with one or two parallel ca Capacitance per unit length max. bles; 0.45 F/km Cables must be shielded 500 m with output reactor (option L08) Cable length (line side) 100 300 m SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Electrical connection 6.5 Connection Table 6-2 Cable cross-sections Object Cross-section Comments Power cable Max. 240 mm Max. six parallel power cables Cabinet protective conductor Max. 120 mm - 2 See also Torques (Page 201) 6.5 Connection 6.5.1 Manually unlocking power-unit doors To ensure operator protection, the drive is equipped with an electromechanical door interlocking system. The doors cannot be opened until the make-proof grounding switch has been closed. In the event of a complete voltage failure including failure of the auxiliary voltage, the doors cannot be released via the grounding switch. Because the drive is not yet connected, the doors are locked electromechanically. In order to facilitate assembly and installation of the drive, the doors can be opened manually. See also Opening the doors (Page 189) 6.5.2 Preparations for connecting the power cables Disconnect the cabinets from the power supply. Ensure that all the necessary safety measures have been taken at the installation location. Allow unimpeded access to the cable clamping bar in the cabinets. 6.5.3 Connecting power cables Note The screws and accessories are not included in the scope of delivery. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 101 Electrical connection 6.5 Connection Contact surface Figure 6-4 Example: Connecting the power cables 1. Clean the contact surfaces immediately before screwing the connections. Use spirit and a lintless cloth for cleaning. 2. Apply a thin film of grease. Electrolube 2G is a suitable lubricator. 3. Screw the cable lug with a M12 screw and, if necessary, with a washer to the contact surface. Tighten the nuts with a torque of 50 Nm. 6.5.4 Connect the power cable to the motor and the supply system 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. Procedure 1. Open the cabinet. 2. Remove or slide away the cover plate for the motor cable penetration. 102 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Electrical connection 6.5 Connection Note To route the power cables from above into the cabinet, remove the cover plate at the top of the cabinet. NOTICE Danger of thermal damage Inadequately fastened cables at the connection point represent a high electrical transfer resistance that can cause thermal damage (contact erosion) during operation. Tighten the screws with the specified torque. 1. Screw the protective ground at the provided locations in the cabinet to the appropriate connection with the ground symbol. Note Connect the motor cables first and then the power cables. 2. Connect the infeed cable to the supply-system connection busbar. 8 : 9 8 : 9 Figure 6-5 Connection of the supply-system power cable 3. Screw the individual phases of the motor cable to the connections below of the output phases. Observe the following connection sequence of the conductors: 1U1, 1V1, 1W1 and 2U1, 2W1, 2V1 Direction of motor rotation Connect asynchronous machines with clockwise phase sequence (looking at the drive shaft) to the drive as follows: Table 6-3 Drive and motor connection terminals Drive (connection terminals) Motor (connection terminals) U2/ U V2/ V W2/ W In contrast to the connection for the clockwise phase sequence, two phases have to be reversed with a counter-clockwise phase sequence (looking at the drive shaft). SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 103 Electrical connection 6.5 Connection Note If an incorrect phase sequence was connected during the cable installation and it cannot be corrected by a subsequent swapping of the motor cables, you have two possibilities: Change the phase sequence by entering a negative setpoint. Change the phase sequence with the drive parameterization. Note Interconnect the windings for motors that can be operated in star-delta correctly. To do this, read the motor documentation. Observe the required isolation voltage for the operation of the drive. 6.5.5 Connecting ground DANGER 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. Each cabinet has a grounding lug for grounding the components installed in the cabinet. It is located at the bottom of the cabinet. Connect the cabinets securely to the plant grounding system via these grounding lugs. Figure 6-6 104 Grounding lug SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Electrical connection 6.5 Connection 6.5.6 Connect the auxiliary voltage Connect the auxiliary voltage 1-phase 230 VAC / 50 Hz Connect the auxiliary voltage for, e.g. SITOP, GSV, closed-loop control, open-loop control, to the terminal strip . The maximum permissible conductor cross-section is 4 mm2. With options C30 - C49, the auxiliary voltage can be drawn from the matching transformer. You will find notes in the circuit manual of the drive. Connect the auxiliary voltage 3-phase 400 VAC / 50 Hz 1. Connect the auxiliary voltage for fans, precharging, etc. to the terminal box . The maximum permissible conductor cross-section is 50 mm2. 2. To connect the cables, move the cover upward. 3. Attach the cables to the appropriate connections. For detailed information, see "Terminal strips" and the circuit manual of the drive. See also Terminal assignments (Page 236) Terminal strip Terminal box Figure 6-7 Connection for auxiliary voltages SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 105 Electrical connection 6.5 Connection 6.5.7 Connecting the encoder to the SMC30 Sensor Module Safety instructions NOTICE Incorrectly connected external encoder If the external encoder is not connected or operated correctly, this can damage the components. Only one measuring system can be connected to each sensor module. The sensor module is wired internally to the customer terminal strip. For further information, see the circuit manual. Note Observe the five safety rules when performing any work. Procedure 1. Allow unimpeded access to the SMC30 Sensor Module. 2. Disconnect the cabinet from the power supply. 3. Route the cables from the encoder into the cabinet from below. 4. Route the cable further up into the cabinet. 5. Connect the encoder cables to the SMC30 Sensor Module. 106 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Electrical connection 6.5 Connection 6. Connect the shield of the encoder cable directly to the shielding bus (serrated bar). It is important here to establish the greatest possible area of contact and a good conductive connection. 7. Attach the shield of the connecting cable to the module . Use metal ground clamps to secure the shield in place. Figure 6-8 Connecting the external encoder to the SMC30 Sensor Module Connection example 1: HTL encoder, bipolar, with reference signal . . . . . . 8E 0 ; 7UDFN$ 7UDFN$ 7UDFN% 7UDFN% 5HIHUHQFHVLJQDO5 5HIHUHQFHVLJQDO5 &75/ Figure 6-9 *URXQG ; (QFRGHUSRZHUVXSSO\9 *URXQGHQFRGHUVXSSO\ Connection example 1: HTL encoder, bipolar, with reference signal SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 107 Electrical connection 6.5 Connection Always use the bipolar connection because its physical transmission properties are more robust. Only if the encoder type employed does not output push-pull signals should you use the unipolar connection. 6.5.8 Interconnecting optional connections Depending on the range of options installed, further connections have to be interconnected. Detailed information about interconnecting these options with the interfaces is provided in the circuit manual. See also Terminal assignments (Page 236) 6.5.9 Connecting the re-cooling unit to the drive Connect the enclosed cable for the cooling unit to the corresponding interfaces on the drive and the cooling unit. Further details are contained in the circuit diagram of the drive and the re-cooling unit. 6.5.10 Fastening the cable ducts with cable ties Fasten all cable ducts whose cover faces downward with cable ties. Wind the cable ties around the entire cable duct. The cable ties must be located at the same positions as in the delivered state. Figure 6-10 108 Schematic diagram: Fastening the cable ties SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 7 Start-up Only personnel trained for this type of drive may commission the drive. WARNING Incorrect commissioning Malfunctions can occur as a result of incorrect commissioning and parameterization. This can result in premature failures and subsequent damage to the drive and the drive system components. This can result in death, serious injury or material damage. Incorrectly performed commissioning can result in the warranty becoming null and void. This drive may only be commissioned by electrical technicians that have been adequately trained on this product, and have experience with commissioning this product and the associated plant and system components. The electrical technician commissioning the equipment must be trained on the specific product as a result of the differences between the individual products, e.g. regarding topology and closed-loop control. Obtain information about the range of SITRAIN training courses available through your local contact person. Make use of the support and services offered by the responsible Siemens Service Center when commissioning this equipment. You can find the relevant contact person under "Service & Support". 7.1 Description and configuration of the PROFIBUS interface 7.1.1 Hardware components required for PROFIBUS communication Set up a PROFIBUS interface to perform the commissioning with STARTER. Required hardware components: Prefabricated PROFIBUS or MPI cable Field PG CP5512 interface adapter (when a laptop is used) CP5611 interface card (when a PC is used) SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 109 Start-up 7.1 Description and configuration of the PROFIBUS interface 7.1.2 PROFIBUS interface, diagnostics LEDs, address switches The PROFIBUS connection, diagnostics LEDs, and the PROFIBUS address switch are located on the CU320 Control Unit. 5'< '3 237 02' 5'< '3, 237 02' X126 PROFIBUS connection PROFIBUS diagnostics LEDs PROFIBUS address switches Figure 7-1 PROFIBUS interface X126 PROFIBUS interface 110 Figure 7-2 X126 PROFIBUS connection Table 7-1 PROFIBUS interface X126 Pin Signal name Meaning 1 - Not assigned Range 2 M24_SERV Power supply for teleservice, ground 0V 3 RxD/TxD-P Receive/transmit data P (B) RS485 4 CNTR-P Control signal TTL 5 DGND PROFIBUS data reference potential 6 VP Supply voltage plus 5 V +- 10% 7 P24_SERV Power supply for teleservice, +24 V 24 V (20.4 V to 28.8 V) 8 RxD/TxD-N Receive/transmit data N (A) RS485 9 - Not assigned SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Start-up 7.1 Description and configuration of the PROFIBUS interface NOTICE Damage to components If CAN cables are connected to the X126 interface, the CU320 or other CAN bus nodes can be damaged. Do not connect any CAN cables to the X126 interface. Note A teleservice adapter can be connected to the PROFIBUS interface X126 for remote diagnostics purposes. The power supply for the teleservice (terminals 2 and 7) can have a load of up to 150 mA. Diagnostics LED The meaning is explained in the table below. Table 7-2 Description of the DP1 LEDs Color Status ----- Off Description Cyclic communication has not (yet) taken place. Note: If the Control Unit is operational, the PROFIdrive is ready for communication. The DP1 LED illuminates. Green Green Continuous light PROFIBUS is ready for communication and cyclic communication is taking place. 0.5 Hz flashing light Full cyclic communication is not yet taking place. The controller is not transferring any setpoints. During isochronous operation, no or a faulty global control (GC) is transferred by the controller. Red Continuous light Cyclic communication has been interrupted. PROFIBUS address switches The PROFIBUS address switch is located under the cover. Figure 7-3 PROFIBUS address switch cover SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 111 Start-up 7.1 Description and configuration of the PROFIBUS interface 7.1.3 Connecting PROFIBUS cables The figure below shows suitable PROFIBUS connectors with/without a programming device/ PC connector. 352),%86FRQQHFWRUV ZLWKRXW3*3&FRQQHFWLRQ (6%$;$ Figure 7-4 352),%86FRQQHFWRUV ZLWKSURJUDPPLQJGHYLFH3& FRQQHFWLRQ (6%%;$ PROFIBUS connectors 1. Connect the cables to the PROFIBUS connector. The bus terminating resistors are located in this connector. 2. Connect the cable shield over a wide area on both sides. Switching the bus terminating resistor on and off 1. Activate the bus terminating resistor at the two ends of the bus line. 2. Deactivate the bus terminating resistor at all other connectors. )LUVWEXVQRGH /DVWEXVQRGH RQ RII RQ RII RQ RII %XVWHUPLQDWLRQ %XVWHUPLQDWLRQ )URPWKHSUHYLRXVEXVQRGH Figure 7-5 112 7RWKHQH[WEXVQRGH Position of the bus terminating resistors SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Start-up 7.1 Description and configuration of the PROFIBUS interface Note Switch the bus terminating resistor on or off depending on its position on the bus, otherwise the data will not be transmitted properly. 7.1.4 Setting the PROFIBUS address switches Set the PROFIBUS address of the CU320 Control Unit for the PROFIBUS communication. You have several options for setting the PROFIBUS address: Parameter p0918 (default setting) - Parameter p0918 can be used to set the PROFIBUS address only when the address is set to 0 or 127 using the DIP switches. Set all switches S1 to S7 to ON or OFF (default setting). If the address is changed, the new setting does not become effective until the CU320 Control Unit is switched on. - The set PROFIBUS address is saved by means of the "Copy RAM to ROM" function. Using the DIP switches on the CU320 Control Unit Move switches S1 to S7 to the required position to set the PROFIBUS address. Switch S1 20 0 1 S2 21 = 2 S3 22 = 4 S4 23 = 8 S5 24 = 16 S6 25 = 32 S7 26 = 64 If you set the PROFIBUS address using the DIP switches S1 to S7, the parameter p0918 is read-only. The parameter shows the set address of the control unit. If the address is changed, the new setting does not become effective until the CU320 Control Unit is switched on. Example of setting the PROFIBUS address using DIP switches In this example, PROFIBUS address 37 is set. 6 6 21 21 2)) 6 6 2)) Example Significance SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 113 Start-up 7.1 Description and configuration of the PROFIBUS interface Note The PROFIBUS address switches have a default setting of 0 or 127 (set via parameter p0918). 7.1.5 Requirements for communication via PROFIBUS To further process the PZD data internally, the PROFIBUS master must always send a 1 in the eleventh bit (bit 10) of the first control word (control by PLC). It is not sufficient to interconnect parameter p854 permanently with a 1. This also applies to slave-to-slave communication between multiple slaves (drive with DC master as an excitation device). The eleventh bit (bit 10) must be preset to 1 in the first control word of the master on the drive. This also applies when no other master control commands are in use and slaves are communicating by direct slave-to-slave data exchange only. 114 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 8 Operation 8.1 Safety instructions for operation Observe Chapter, "Safety instructions" when carrying out any work at the converter. DANGER Operation with the doors open High voltages are present in the drive and its components during operation and also after it has been switched off. When touched, these voltages can lead to death or severe injury. Ensure that no voltage is present when the doors of the power unit are open. Never operate the drive with doors open. WARNING Faults Operating the converter when a fault has arisen can result in death, serious injury or substantial material damage. Observe the fault and alarm messages. Eliminate the source of the fault. Only put the converter back into operation once this is resolved. You can find further information on alarms and faults in the section "Indicating and rectifying faults." If it is not possible to correct a fault, inform the manufacturer's service personnel immediately. For additional information, see Chapter "Service & support". WARNING Unpermitted operation with ground fault The type and location of the fault cannot be established just from a ground fault error message. For example, the glow discharge at the winding overhang of the machine may result in a fault signal. In the event of continued operation, serious aftereffects all the way to electric arcs are possible. This can result in death, serious injury or material damage. If a ground fault is experienced during drive operation, the drive must be switched off immediately. Then identify and eliminate the source of the ground fault. The plant operating company is responsible for the consequences, if the drive is still operated after a ground fault has been detected. Carry out a risk analysis. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 115 Operation 8.2 Operation via the AOP30 operator panel WARNING Exceeding the permitted short-circuit currents Serious follow-on faults are possible, if the specified short-circuit current values are exceeded. This can result in death, serious injury or material damage. Observe the maximum permitted short-circuit currents and maximum specified short-circuit times. NOTICE Incorrect parameterization The drive may malfunction if you change the parameters. Do not change the parameters, e.g. for the motor circuit-breaker. Note To complement these operating instructions, the List Manual contains an overview of all parameters as well as a selection of function diagrams to describe the operating principle. Only trained personnel should be allowed to operate the drive. This section describes basic operating procedures performed via the AOP30 operator panel. 8.2 Operation via the AOP30 operator panel 8.2.1 General information about the AOP30 operator panel 8.2.1.1 AOP30 operator panel You can use the Advanced Operator Panel (AOP30) for operating, and diagnosing the drive. The AOP30 communicates with the drive via a serial RS-232 interface with PPI protocol. The interface is a point-to-point connection. The AOP30 has the master function in this communication. The connected drive has the slave function. 116 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Operation 8.2 Operation via the AOP30 operator panel Functions of the AOP30 Figure 8-1 AOP30 operator panel The AOP30 has the following features and functions: Graphics-capable LCD with the following features - Green backlighting for plain-text display - Resolution of 240 x 64 pixels - Quasi-analog bar-type display for process variables Keypad for operational control of a drive Numeric keypad for the numeric input of parameter values 4 LEDs for indicating the operating state of the drive unit: - RUN: green - ALARM: yellow - FAULT: red - LOCAL/REMOTE: green Help function describing causes of and remedies for faults and alarms Function keys for prompted navigation through the menus Realtime clock for the time stamping of faults and for setting up simple time controls LOCAL/REMOTE switchover for selecting the operating location Two-stage security concept to protect against unintentional or unauthorized changes to settings. Time and date memory powered by internal battery backup SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 117 Operation 8.2 Operation via the AOP30 operator panel 8.2.1.2 Buttons of the AOP30 Functions of the control keys Calls the main menu of the AOP30. 0(18 Calls the "inhibit functions" menu. /2&$/ 5(027( Numeric keys for direct entry of values. Switches between remote and local mode. In local operation, the LED illu minates. On/off If no operator inhibit is activated, then the "On" button in local operation is always active. The "Off" button is only active in local operation, and in the factory setting acts as "OFF1". Counterclockwise-clockwise switchover The button is only active in local mode. -2* ) ) JOG (Jogging) The key is only in effect in local mode in "Ready to switch on" status (not when "operating"). The system is accelerated to the setpoint speed. Setpoint "increase" and setpoint "decrease". You can enter the setpoint using these buttons. Alternatively, you can enter the setpoint using the alphanumeric keys. Using the numeric keypad, any speed ranging between the maximum and minimum speed can be entered. Function keys. These keys have different functions depending on the menu. The respec tive function appears in plain text above the key. See also Control settings (Page 125) Inhibit functions (Page 128) 8.2.1.3 Basic operation of the AOP 30 The menu structure Operation of the AOP 30 is menu-driven. To make it easier to find a menu, the following figure shows the menu structure. 118 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Operation 8.2 Operation via the AOP30 operator panel The menu displays marked with * only appear if you set the "special access" access level. More detailed information is available in the "Inhibit functions" section. &XUUHQWIDXOWV 0DLQPHQX &XUUHQWDODUPV 2OGIDXOWV +HOS 6HO3DU 2SHUDWLRQVFUHHQ &KDQJH 2OGDODUPV %DVLFFRPPLVVLRQLQJ &RPSOHWHFRPPLVVLRQLQJ 0RWRULGHQWLILFDWLRQ 'LDJ 5HVHWIDQRSHUDWLQJWLPH 5HDG\ ,QGLYLG'2 'HYLFHFRQILJXUDWLRQ 'HILQLWLRQRIGULYHW\SH 'ULYHEDVHFRQILJXUDWLRQ 'DWDVHWEDVHFRQILJXUDWLRQ $OO'2 3DUDPHWHUUHVHW 3DUDPHWHUL]H '2VHOHFWLRQ &RQWUROVHWWLQJV 3DUDPHWHUL]DWLRQ 3HUPDQHQWSDUDPHWHU WUDQVIHU $GYDQFHGVHWWLQJV 'ULYH FRPPLVVLRQLQJ 'HYLFH FRPPLVVLRQLQJ $23 VHWWLQJV $23 GLDJQRVWLFV /DQJXDJH Figure 8-2 'HILQHRSHUDWLRQVFUHHQ 6HWGDWHWLPH )DXOW DODUPPHPRU\ &RPPLVVLRQLQJ VHUYLFH 'LVSOD\VHWWLQJV 5HVHW$23VHWWLQJV 6RIWZDUHGDWDEDVHYHUVLRQ %DWWHU\VWDWXV &RPPXQLFDWLRQ .H\ERDUGWHVW /('WHVW )RUPDWIODVK)6 &OHDUSHUVLVWHQWGDWDEDVH Menu structure of the AOP 30 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 119 Operation 8.2 Operation via the AOP30 operator panel The function keys Press the appropriate function key for navigation, for inputs and to change values within the menus. The associated assigned function is written in plain text above the corresponding function key. 581 'HILQHRSHUDWLRQVFUHHQ $/$50 2SHUVFUHHQW\SH )$8/7 6FUHHQW\SH 6FUHHQYDOXHV F1 +HOS EDUV &KDQJH F4 F3 F2 %DFN F5 Figure 8-3 Function keys of the AOP 30 Changing parameters Press the appropriate function key . The assigned function can vary from menu to menu. For example, the <F5> function key is assigned the <OK> or < change> functions. 1. Using the function keys , , , select the parameter that you want to change. 2. To change the selected parameter, activate the parameter according to the menu. Press the <OK> function key. Use either the numeric keypad or the function keys to modify the selected parameter. <>,< >, <>, <>. 3. You must confirm the change according to the menu. Press the <OK> function key. 4. Press the <Back> function key to scroll back to the main menu. Press the <MENU> function key to directly call the main menu. Calling up parameter Help 1. Press the <> or <> function key to select the desired parameter. 2. Press the <Help> function key. 3. Press the <> or <> function key to select the desired Help topic. 4. Press the <OK> function key to call the selected Help topic. 5. Press the <Back> function key to exit the Help function. 120 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Operation 8.2 Operation via the AOP30 operator panel 8.2.2 Configuration of the AOP30 operator panel 8.2.2.1 Define operation screen Depending on the type of drive, an operation screen with ten different display parameters is the default. 9(&725 2)) 9B'& 9 $867 3:,5. N: 7B/7 r& ,4,67 $HII +HOS Figure 8-4 FKDQJH ,B,7 )B2)) /7,7 ,',67 8B2)) 6HO3DU $HII +] $HII 9HII 'LDJ Example of the operation screen You can customize the display of the operation screen. The following types of display are available: Values - 2 digital values - 10 values The order of the entries in this screen determines the order of the operating variables (parameters) displayed in the operation screen. Bars - 3 bars Mixed - 8 values / 1 bar - 4 values / 2 bars Order of the display: First the parameters to be displayed digitally and then the parameters to be displayed as bars. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 121 Operation 8.2 Operation via the AOP30 operator panel Defining the operation screen 1. Press the <Change> function key. The "Operation screen" menu opens. 'HILQHRSHUDWLRQVFUHHQ 6FUHHQW\SH $FWLYH 2SHUVFUHHQW\SH 6FUHHQW\SH YDOXHV%DUV +HOS &KDQJH %DFN 2. Press the <> or <> function key to select the "Screen 2" entry. Then press the <Change> function key to change the "Active" setting. 3. Press the <> or <> function key to select the "Screen 2 type" entry. Then press the <Change> function key to select the desired display type. 4. Press the <> or <> function key to select the "Screen 2 values" entry. Then press the <Change> function key to activate the setting. 'HILQHRSHUDWLRQVFUHHQ 6FUHHQW\SH DNWLY 2SHUVFUHHQW\SH 6FUHHQW\SH 6FUHHQYDOXHV +HOS 9DOXHV%DUV %DFN &KDQJH - The display changes to the menu for entering the parameters. 2SHUDWLRQVFUHHQ U U , B ,67 U $8667 $XVVWHXHUJUDG JO U )B $86 $QWU IB $XVJ JOD 122 3%6(7 3% 3=' HPSI 9RU , B LVW %DFN %HWUDJ JO &KDQJH SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Operation 8.2 Operation via the AOP30 operator panel 5. Press the <> or <> function key to select the first parameter. Then press the <Change> function key to activate the setting. The display changes to the menu for selecting the DriveObject (DO). 'HILQHRSHUDWLRQ U 3%62// 3%3='HPSI9RU %,&2'2VHOHF &8 U *0 % B ,1)12 U 9(&72509 U +HOS , B ,67 , B LVW %HWUDJ JO $8667 $XVVWHXHUJUDG JO )B $86 $ QWU IB $XVJ JOD &DQFHO 2. 6. Press the <> or <> function key to select the desired DO. Then press the <OK> key to confirm the setting. The "Parameter selection" menu opens. 'HILQHRSHUDWLRQ &8B*06HOHFWLQJSDUDPHWHUV $OOSDUDPHWHUV U 3%3='HPSI:RUG +HOS %DFN 2. 7. You have two parameter selection options: - All parameters of the selected DO Press the <> function key to select "All parameters". Then confirm the selection with OK. A list of all parameters of the selected DO is displayed. - Selection of plausible parameters (see "List of the signals for the operation screen" below) of the selected DO. Select a parameter from the list of the signals for the operation screen of the selected DO. The selected parameters from this list are displayed in the operation screen with an abbreviated name (e.g. NSOLL). 8. Select the desired parameter or enter the parameter from the numeric keypad. 9. Confirm the setting by pressing the <OK> function key. The "Please wait" message appears briefly. Then the operation screen appears in the configuration you set. 9(&725 $86 3%62// ,B,67 $HII $867 )B$86 +] 3:,5. N: /7,7 +HOS 'LDJ 6HO3DU &KDQJH SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 123 Operation 8.2 Operation via the AOP30 operator panel List of signals for the operation screen Table 8-1 List of signals for the operation screen Signal Parameter Short name Unit Scaling (100% = ...) Speed setpoint upstream of RFG (1) r1114 NSETP 1/min p2000 Output frequency (2) r0024 F_OUT Hz Reference frequen cy Output smoothed (3) r0032 P_ACT kW r2004 DC-link voltage smoothed (4) r0026 UDC V p2001 Actual speed smoothed (5) r0021 N_ACT 1/min p2000 Actual absolute current smoothed (6) r0027 I_IST A p2002 Motor temperature (7) r0035 T_MOT C Reference tempera ture Motor temperature (8) r0037 T_LT C Reference tempera ture Actual torque smoothed (9) r0031 M_ACT Nm p2003 Drive output voltage smoothed (10) r0025 C_OUT V p2001 Speed setpoint smoothed r0020 NSETP 1/min p2000 Control factor smoothed r0028 % Reference control factor Field-producing current component r0029 A p2002 Torque-producing current component r0030 A p2002 Drive overload Degree of thermal overload r0036 % 100% = Shutdown Speed setpoint motor encoder r0061 N_ACT 1/min p2000 Speed setpoint after filter r0062 N_ACT 1/min p2000 Actual speed smoothed r0063 N_ACT 1/min p2000 Control deviation r0064 1/min p2000 Slip frequency r0065 Hz Reference frequen cy Output frequency r0066 Hz Reference frequen cy Output voltage r0072 V p2001 Control factor r0074 % Reference control factor Torque-generating actual current r0078 A p2002 Actual torque value r0080 Nm p2003 Fixed speed setpoint effective r1024 1/min p2000 Active motor potentiometer setpoint r1050 1/min p2000 Resulting speed setpoint r1119 1/min p2000 Speed controller output r1508 Nm p2003 I component of speed controller r1482 Nm p2003 DO: Vector MV Factory setting (entry no.) 124 UACT SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Operation 8.2 Operation via the AOP30 operator panel Signal Parameter Short name Unit Scaling (100% = ...) PROFIBUS setpoint r2050 1/min p2000 Torque utilization smooth r0033 MUTIL % Motor temperature r0035 T_MOT C Torque utilization r0081 MUTIL % Speed setpoint r1169 NSETP 1/min p2000 Speed setpoint sum r1170 NSETP 1/min p2000 2050 PBSOL Vdc smooth r0026 VDC V p2001 Power Module temperatures r0037 LT T C Line frequency r66 fLine Hz PROFIBUS setpoint r2050 PBSOL PROFIBUS setpoint r2050 PBSOL Analog inputs U/I r4052 AI_UI Analog inputs % r4055 AI_% DO: CU_GM PROFIBUS setpoint DO: B_InfMV DO: TM31 % Scaling Table 8-2 Scaling Variable Scaling parameter Default for quick commissioning Reference speed 100% = p2000 p2000 = Maximum speed (p1082) Reference voltage 100% = p2001 p2001 = 1000 V Reference current 100% = p2002 p2002 = Current limit (p0640) Reference torque 100% = p2003 p2003 = 2 x rated motor torque Reference power 100% = r2004 Reference frequency Reference control factor 100% = Maximum output voltage without overload Reference flux 100% = Rated motor flux Reference temperature 100% = 100 C 8.2.2.2 Control settings You can set the control keys of the AOP as desired. 1. Press the <MENU> key. 2. Press the or function key to select the <Commissioning/service> entry. 3. Press the <OK>. function key and the function key to select the <AOP settings> entry. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 125 Operation 8.2 Operation via the AOP30 operator panel 4. Press the function key to select the <Control settings> entry from this menu. The display changes to the Control settings menu. &RQWUROVHWWLQJV 6DYH/2&$/PRGH 1R DNWLY 2IILQ5(027( /2&$/5(027(DOVRGXULQJRSHU 5HG2))NH\DFWVDV +HOS &KDQJH 1R 1R 2)) %DFN 5. Press the or function key to select the desired entry. Press the <Change> function key to change the setting. 6. Press the <Back> function key to confirm the entries. You can find the description and setting options for the individual menu items in the following. Saving LOCAL mode Setting "Yes" (default setting): The LOCAL operating status is saved when the power supply is switched off and restored the next time power is switched on. Setting "No": The REMOTE operating status is activated when the supply voltage is switched back on. Off in remote Setting "Yes": It is possible to switch off in remote mode by pressing the <OFF> key. Setting "No": The <OFF> key has no effect in remote operation. The <OFF> key is always active in LOCAL mode. LOCAL/REMOTE also during operation Setting "Yes": You can switch between LOCAL and REMOTE when the drive is switched on (i.e. motor is running). Setting "No" (default setting): Before the system switches to LOCAL, a check is carried out to determine whether the drive is in the operational status. In this case, the system does not switch to LOCAL and outputs the error message "Local mode during operation not possible". Before the system switches to REMOTE, the drive is switched off and the setpoint is set to 0. 126 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Operation 8.2 Operation via the AOP30 operator panel Red OFF key acts as OFF1 - Ramp-down on the deceleration ramp (p1121). OFF1 is the default setting. OFF2 - Immediate pulse block, motor coasts to a standstill. OFF3 - Ramp-down on the emergency stop ramp (p1135). The OFF key is only effective in LOCAL mode. Red OFF key also in REMOTE Setting "Yes": It is possible to switch off in remote mode by pressing the <OFF> key. Setting "No": The <OFF> key has no effect in REMOTE operation. In LOCAL mode, the OFF key is always in effect. Clockwise/counter-clockwise switchover Setting "Yes": In LOCAL mode, left/right switching is possible using the key. Setting "No" (default setting): The key does not act in LOCAL mode. In REMOTE mode, the key is always in effect. For safety reasons, the left/right key is inactive in the default setting. Pumps and fans may normally be operated only in one rotational direction. In the "Operation" state in LOCAL mode, the current rotational direction is indicated by an arrow next to the operating mode. JOG key active (jogging) Setting "Yes": In LOCAL mode, in the "Ready to switch on" state (not in "Operation" state), jogging mode is possible using the <JOG> key. The speed set in parameter p1058 is approached. Setting "No": The <JOG> key has no effect in LOCAL mode. The <JOG> key never acts in REMOTE mode. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 127 Operation 8.2 Operation via the AOP30 operator panel Save AOP setpoint Setting "Yes": In LOCAL mode, the and keys save the set setpoint. The set value is automatically reset as the setpoint value after the power supply is switched off and on again. During the switchover from REMOTE to LOCAL mode with the drive switched on (motor running), the current actual value is set as the AOP setpoint and saved. During the switchover from REMOTE to LOCAL mode with the drive switched off, the last saved AOP setpoint is used. Setting "No": In LOCAL mode, after switching the drive off and on, "0" is set as initial value for the AOP setpoint. "0" is also set as initial value for the AOP setpoint after the power supply has been switched off and on. The current value is set as AOP setpoint when switched from REMOTE to LOCAL mode for activated drive and running motor. AOP ramp-up time/AOP ramp-down time The AOP ramp-up time setpoint and the AOP ramp-down time setpoint specify in which time the <+> and <-> keys change the AOP setpoint. The ramp-up time acts when the setpoint changes from smaller to larger, i.e positive or negative values. The ramp-down time acts in the opposite direction. The times set here act in addition to the ramp-up and ramp-down times set in the drive. The default setting for the AOP ramp-up time is 20 seconds. The default setting for the AOP ramp-down time is 30 seconds. Recommendation: Set the ramp-up/ramp-down time just as for p1120/p1121. Adjusting the AOP ramp-up/ramp-down time does not affect the setting of parameters p1120/p1121, because this is an AOP-specific setting. Definition of the ramp-up/ramp-down time: Example: With the ramp-up time set at 50 s, the maximum setpoint is reached by pressing the <+> key in 50 s. 8.2.2.3 Inhibit functions For protection against improper setting of the parameters or accidental use of the control keys, you can activate various inhibit functions. 128 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Operation 8.2 Operation via the AOP30 operator panel The menu structure of the inhibit functions 2SHUDWH/RFN 3DUDPORFN 6DIHW\ORFNV $FFHVVOHYHO Calling up the inhibit function menu 1. Press the key with the key symbol. 6DIHW\ORFNV 2SHUDWHORFN 3DUDPORFN $FFHVVOHYHO +HOS QRWBDFWLYH QRWBDFWLYH &KDQJH 6WDQGDUG &KDQJH %DFN &KDQJH The various inhibit functions are described in the following. Operator input inhibit Parameters can only be changed by entering a password. 1. Press the <> or <> function key to select the "Operator input inhibit" function. 2. Press the <Change> function key to select the "active" or "inactive" setting. - "active" The contents of parameters can be viewed, but not saved. If you want to save a parameter, this message appears: "Note: Inhibit function active". The <OFF> key acts. The <LOCAL/REMOTE>, <LEFT>, <RIGHT>, <UP> and <DOWN> keys are inhibited. The key symbol indicates the inhibit. - "inactive" No operator input restrictions. 3. Press the <Back> function key to save the setting. Parameterization inhibit Prevent unauthorized parameterization. This function is protected with a password. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 129 Operation 8.2 Operation via the AOP30 operator panel It is possible to control the drive. 1. Press the <> or <> function key to select the "Parameterization inhibit" function. 2. Press the <Change> function key to select the "active" or "inactive" setting. - "active" A window appears on the display for entering and confirming a password. Enter an identification number (up to 7 digits). The contents of parameters can be viewed, but not saved. If you want to save a parameter, this message appears: "Parameterization inhibit - no control command acceptance". The control keys are not disabled. The key symbol indicates the inhibit. If you have forgotten the password, switch off the parameterization inhibit as follows: 1. Switch off the power supply. 2. Pull out the RS232 data cable. 3. Switch on the power supply. Press the key with the key symbol for 20 seconds. The key symbol extinguishes. The operation is not restricted. 4. Press the <Back> function key to save the setting. Access level The scope of the displayed parameters conforms to the set access level. The access level determines which parameters can be displayed and changed. The higher the access level, the more functions that are available. The following access levels are possible: Access level Functions 1: Standard Sufficient for simple applications. The default setting is "1 standard". 2: Extended 3: Expert The structure of the function can be changed by interconnecting BICO parame ters. Only experts should make this setting. 4: Special access This setting is only used for service purposes. A password is required upon acti vation. 1. Press the <> or <> function key to select the "Access level" function. 2. Press the <Change> function key to select the desired access level. 3. Press the <Back> function key to exit the menu. Note Changing the access levels During the device commissioning, prior to a change of the access level, e.g. from access level 2 to access level 3, select the status "0: ready)". For further information, refer to the Commissioning / service device commissioning section. 130 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Operation 8.2 Operation via the AOP30 operator panel 8.2.3 Menu description and setting options The individual menus of the AOPs with their setting options are described in the following. To make things easier for you, the respective section of the menu structure is illustrated at the beginning of each chapter. 8.2.3.1 Operation screen The menu structure of the operation screen 0DLQPHQX +HOS &XUUHQW IDXOWV 6HO3DU &XUUHQW DODUPV &KDQJH 2OGIDXOWV 'LDJ 2OGDODUPV 2SHUDWLRQVFUHHQ Figure 8-5 Menu structure of the operation screens The operation screen The operation screen displays the most important status variables for the drive: In the factory setting, the following values are displayed: Operation status of the drive Direction of motor rotation Time Ten parameters (numerical display) 9(&725 2)) 9B'& 9 $867 3:,5. N: 7B/7 r& ,4,67 $HII +HOS FKDQJH ,B,7 )B2)) /7,7 ,',67 8B2)) 6HO3DU $HII +] $HII 9HII 'LDJ Operation screen SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 131 Operation 8.2 Operation via the AOP30 operator panel Calling up operation screens There are three options for calling up the operation screens: Once the system has started, press the <F5> key. Wait for five minutes (do not press any buttons). The Operation screen is called up automatically. In the main menu, select "Operation screen". Press the <Select> function key. Note When there is a fault, the fault screen is automatically displayed. Further settings You can adjust the shape of the display and the displayed values to your liking. You can find more detailed information in the "Defining operation screens" section. The other menus of the operation screen The menus that you can call up from the operation screen using the function keys are described below. Function key Function Sel. Par. Selects a parameter (value or bar) of the operation screen. Help Call up of an explanatory help text for the selected display. This help text de scribes, e.g. which parameter forms the basis for the display. change Open the "Define operation screen" menu. You can find more detailed information in the "Defining operation screens" sec tion. Diag. Opens the "Fault memory/alarm memory" menu. In this menu, the queue of active faults and alarms is displayed. You can find further information on alarms and faults in the "Alarms and faults" section. You can select the following fault and alarm menus. Current faults This menu shows the number and title of the currently active faults. 1. Press the <Help> function key to fetch information about correcting the fault. 2. Press the <Ack.> function key to acknowledge the fault. Current alarms This menu shows the number and title of the currently active alarms. 1. Press the <Help> function key to fetch information about correcting the alarm. 132 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Operation 8.2 Operation via the AOP30 operator panel Old faults This menu displays the number and titles of the old faults. The top row shows the following information. The total number of faults. The time when the fault occurred. The faults are displayed in ascending order in separate screens. 1. Press the <Tools+> key. Select "older" or "newer" to fetch the fault messages arranged chronologically. 2. Press the <Help> function key to fetch information about correcting the fault. Old alarms This menu displays the number and titles of the old alarms. The top row shows the following information: The total number of alarms. The time when the alarm occurred. The alarms are displayed in ascending order in separate screens. 1. Press the <Tools+> key. Select "older" or "newer" to fetch the alarms arranged chronologically. 2. Press the <Help> function key to fetch information about correcting the alarm. 8.2.3.2 Parameterization Parameterization menu structure The menus that you can call from the "Parameterization" menu using the function keys are described below. 0DLQPHQX ,QGLYLG'2 $OO'2 3DUDPHWHUL]DWLRQ 3DUDPHWHUL]H '2VHOHFWLRQ 3HUPDQHQWSDUDPHWHU WUDQVIHU Figure 8-6 Parameterization menu structure SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 133 Operation 8.2 Operation via the AOP30 operator panel Calling up the parameterization menu 1. Press the "MENU" key. 2. Press the <> function key to select the "Parameterization" row. Press the <OK> function key to confirm the selection. 3. Press the <> or <> function key to select the desired function. Press the <OK> function key to confirm the selection. Individual DO The "Individual DO" function opens the parameter lists for the individual DriveObjects (DO). 1. Press the <> or <> function key to select the desired DO. Confirm the selection with <OK>. 2. Press the <> or <> function key to select the desired parameter. Alternatively, you can select the parameter by entering the parameter number on the keypad. Parameters with identical functions may exist with the same parameter number in more than one drive object (e.g. p0005). 3. Press the <Change> function key to open the change window of the parameter. You can change the parameter by assigning values or by making a selection from a list. 4. Press the <Help> function key to fetch information about the selected parameter. All DOs The "All DOs" function displays a list of the parameters of all the DriveObjects (DO) sorted numerically. In this list, the same parameter number can appear several times. At the top left, you see the number of the DO to which the parameter belongs in brackets. 1. Press the <> or <> function key to select the desired parameter. Alternatively, you can select the parameter by entering the parameter number on the keypad. Parameters with identical functions may exist with the same parameter number in more than one drive object (e.g. p0005). 2. Press the <Change> function key to open the change window of the parameter. You can change the parameter by assigning values or by making a selection from a list. 3. Press the <Help> function key to fetch information about the selected parameter. 134 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Operation 8.2 Operation via the AOP30 operator panel Selecting data sets 'DWDVHWVHOHFWLRQ 7\S &RPPDQG'6 'ULYH'6 0RWRU'6 F G P +HOS 0D[ 'ULYH $23 %DFN 2. Figure 8-7 Selecting data sets In this menu, you can parameterize the following data sets: Command data set Drive data set Motor data set Speed encoder data set Power unit data set The data set number set for "AOP" specifies which index (data set) of the assigned parameter in the AOP is displayed. This is independent of which data set is currently activated in the drive. Example of a data set selection You can set separately the main setpoints in the terminal mode and PROFIBUS mode using two command data sets. This requires that you have parameterized this beforehand. In terminal mode p1070[1] 1), REMOTE MODE 1 In PROFIBUS mode p1070[0] 1), REMOTE MODE 0 The command data set that must be enabled for setting the relevant main setpoint is indicated in the square parentheses of the parameter [ ]. In the factory setting, command data set 0 is active. 1) Permanent parameter acceptance The parameters are saved on the CompactFlash card using this menu. You can find further information on this in the "Permanently saving the parameters" section. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 135 Operation 8.2 Operation via the AOP30 operator panel 8.2.3.3 Fault/alarm memory Menu structure of the fault memory/alarm memory menu 0DLQPHQX )DXOW DODUPPHPRU\ Figure 8-8 Menu structure for fault memory/alarm memory Alarm overview If a fault occurs, the drive displays the associated faults and/or alarms on the operator panel in the "Alarm overview". 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). The diagram below shows that currently at least one active fault/alarm is present for the "VECTOR" drive object. The two other drive objects are fault-free. $ODUPRYHUYLHZ &8B* 9(&725 70 )DXOW $ODUP 7RROV 'LDJ 1. Press the <Diag.> function key to display the "Display diagnostics" menu. In this menu the current and old faults and alarms are displayed. ^9(&725'LVSOD\GLDJQRVWLFV 2OGIDXOWV &XUUHQWDODUPV 2OGDODUPV 2OGIDXOWV %DFN 2. You can find further information on alarms and faults in the "Operation screens" section. 136 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Operation 8.2 Operation via the AOP30 operator panel What is a fault? A fault is a message from the drive indicating an error or an other exceptional (unwanted) status. The cause can be a drive-internal fault or an external fault. The 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 via PROFIBUS. In the factory default setting, the message "drive fault" is also sent to a relay output. Once you have eliminated the cause of the fault, acknowledge the fault message. The list of faults and alarms indicates the type of response (e.g. OFF1, OFF2) for each fault message. Displaying faults Faults are displayed by the red "FAULT" LED. Any faults that have occurred are automatically displayed. Up to eight faults occurring at the same time are displayed. 1. Use the <> or <> function key to select the fault. 2. Press the <Ack.> function key to acknowledge the fault. The operation screen is displayed. 3. Press the <Help> function key to fetch the information for clearing the fault. 9(&725 )DXOWV ) ) +DXSWQHW]VFKDOWHUB (UGVFKOXVV6WUXQJ +HOS %DFN 4XLWW What is an alarm? An alarm is the response to a fault condition identified by the drive that does not result in the drive being shutdown. Alarms do not need to be acknowledged. Alarms are "self acknowledging", that is, they are reset automatically when the cause of the alarm has been eliminated. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 137 Operation 8.2 Operation via the AOP30 operator panel Displaying alarms Alarms are displayed by the yellow "ALARM" LED. Additionally, an appropriate note relating to the cause is displayed on the operator panel. Up to eight alarms occurring at the same time are displayed. 9(&725 )DXOWV + (UGVFKOXVVZDUQXQJDFWLY %DFN +HOS Figure 8-9 8.2.3.4 &OHDU Alarm screen Commissioning / service device commissioning Commissioning / service / device commissioning menu structure 0DLQPHQX 5HDG\ 'HYLFHFRQILJXUDWLRQ &RPPLVVLRQLQJ VHUYLFH 'HYLFH FRPPLVVLRQLQJ 'HILQLWLRQRIGULYHW\SH 'ULYHEDVHFRQILJXUDWLRQ 'DWDVHWEDVHFRQILJXUDWLRQ 3DUDPHWHUUHVHW Figure 8-10 Commissioning / service / device commissioning menu structure 1. Press the <<MENU>> key. 2. Press the <> function key to select the "Commissioning/Service" row. Press the <OK> function key to confirm the selection. 3. Press the <> function key to select the "Device commissioning" row. Press the <OK> function key to confirm the selection. - The menus marked with "*" appear only when the "special access" access level was selected 138 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Operation 8.2 Operation via the AOP30 operator panel Device commissioning menu This expert menu supports the device commissioning controlled via p0009. 1. Select a commissioning level. - The parameters that can be written in the enabled commissioning level are displayed. This makes it easier for you to make changes, such as switching over units or activating function modules. 2. Set the p0009 parameter to 0: Ready to finish commissioning. 'HYLF HF RPPLVVLRQLQJS 5HDG\ 'HYLFHFRQILJXUDWLRQ 'HILQLWLRQRIGULYHW\SH 'ULYHEDVHFRQILJXUDWLRQ 'DWDVHWEDVHFRQILJXUDWL +HOS %DFN 2. 3. Press the <> or <> function key to select the desired parameter. Confirm the selection with <OK>. 0: Ready = The device commissioning is closed. 1: Device configuration = At the first commissioning of the device, after start-up, the device is in the "device configuration" status. Transfer the identification for the actual topology (r0098) to the identification for the setpoint topology (p0099). To do this, it is sufficient to set a single index value of p0099[x] the same as r0098[x]. No other parameter may be changed prior to the commissioning. To start the internal automatic first device commissioning, set p0009 = 0 (ready). After the first commissioning has been carried out, in this status, other basic device configuration parameters can be adjusted (e.g. the basic sampling time in p0110) if required. 2: Specification of the drive type = You can change or select the drive object types and/or the function modules for individual drive objects. To do this, set the drive object type with p0107[0...15] and the function module with p0108[0...15]. Further details can be found in the parameter p0101[0...15]. 3: Drive basic configuration = After the device has been commissioned for the first time, basic changes can be made for the individual drive objects (e.g. sampling times in p0111, p0112, p0115 and the number of data sets in p0120, p0130, p0140, p0170, p0180). 4: Data basis configuration = After the first commissioning of the device, you can change the individual drive objects: - Assignment of the components (p0121, p0131, p0141, p0151, p0161) to the individual data sets. - Assignment of the power unit, motor and encoder to the drive data sets (p0185, ...). 30: parameter reset = In order to bring the complete unit into the "first commissioning" status or to load the parameters saved with p0977, p0009 must first be set to this value. p0976 can then be changed to the required value. You will find a list of the settable parameters below. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 139 Operation 8.2 Operation via the AOP30 operator panel Overview of the important parameters (list manual) Table 8-3 Parameter Overview of important parameters (equipment commissioning) Parameter text Device configuration p0092 Synchronous PROFIBUS operation, pre-assignment/check p0097 Select drive object type r0098[0] Device actual topology, DRIVE-CLiQ socket X100 p0099[0] Device setpoint topology, DRIVE-CLiQ socket X100 p0101[0] Drive object numbers, drive object number Control Unit p0978[0] List of drive objects p2042 PROFIBUS ID number p9904 Topology comparison, acknowledge differences p9905 Device specialization p9906 Topology comparison, comparison stage of all components p9907 Topology comparison, comparison stage of the component number p9908 Topology comparison, comparison stage of a component p9909 Topology comparison, component replacement p9910 Taking on additional components in the setpoint topology p9915 DRIVE-CLiQ data transfer error, shutdown threshold, master p9916 DRIVE-CLiQ data transfer error, shutdown threshold, slave Definition of drive type DO CU_GM P0103[0] Application-specific view p0107[0] Drive objects type, drive object Control Unit p0108[0] Drive objects function module, function module Control Unit Drive data basic configuration DO VECTORMV p0112 Sampling time pre-setting p0115 p0115[0] Sampling times for internal control loops, current controller r0116[0] Drive object clock recommended, changes only for current drive object p0120 Number of Power Module data sets (PDS) p0130 Number of Motor data sets (MDS) p0140 Number of Encoder data sets (EDS) p0170 Number of Command data sets (CDS) p0180 Number of Drive data sets (DDS) r6672[0] Switch switch-on time measured, switch 0 r6673[0] Switch switch-off time measured, switch 0 p6674[0] Switch switch-on monitoring time, switch 0 p6675[0] Switch switch-off monitoring time, switch 0 p6681[0] Switch On/Off commands pulse time, switch 0 p6683[0] Switch bounce time, switch 0 DO B_Inf 140 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Operation 8.2 Operation via the AOP30 operator panel Parameter Parameter text p0112 Sampling time pre-setting p0115 p0115[0] Sampling times for internal control loops, current controller p0120 Number of Power Module data sets (PDS) p0170 Number of Command data sets (CDS) r6672[0] Switch switch-on time measured, switch 0 r6673[0] Switch switch-off time measured, switch 0 p6674[0] Switch switch-on monitoring time, switch 0 p6675[0] Switch switch-off monitoring time, switch 0 p6681[0] Switch On/Off commands pulse time, switch 0 p6683[0] Switch bounce time, switch 0 DO CU-GM p0115[0] Sampling times for additional functions, basic sampling time r0116[0] Drive object clock recommended, changes only for current drive object p0799 CU inputs/outputs, sampling time P4099 TM15 DI/DO inputs/outputs, sampling time TM15DI_DO Data basic configuration DO CU_GM r0197 Loader 1 version r0198 Loader 2 version DO VECTORMV p0121[0] Power module component number r0126[0] Power unit components active/inactive p0131[0] Motor component number p0141[0] Encoder interface (Sensor Module) component number p0142[0] Encoder component number p0145[0] Enable/disable encoder interface p0146[0] Encoder interface active/inactive p0186[0] Motor data set (MDS) number p0187[0] Encoder 1 encoder data set number p0188[0] Encoder 2 encoder data set number p0189[0] Encoder 3 encoder data set number TM15DI_DO p0151 Terminal Module component number Note Changing the access levels During the device commissioning, prior to a change of the access level, e.g. from access level 2 to access level 3, select the status "0: ready)". For further information, refer to the Commissioning / service device commissioning section. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 141 Operation 8.2 Operation via the AOP30 operator panel 8.2.3.5 Commissioning / service drive commissioning Commissioning / service / drive commissioning menu structure %DVLF FRPPLVVLRQLQJ 0DLQPHQX &RPPLVVLRQLQJ VHUYLFH &RPSOHWH FRPPLVVLRQLQJ 'ULYH FRPPLVVLRQLQJ 0RWRU LGHQWLILFDWLRQ 5HVHWIDQ RSHUDWLQJWLPH Figure 8-11 Commissioning / service / drive commissioning menu structure 1. Press the <Menu>. key 2. Press the <> function key to select the "Commissioning/Service" row. Press the <OK> function key to confirm the selection. 3. Press the <> function key to select the "Device commissioning" row. Press the <OK> function key to confirm the selection. 4. Press the <> function key to select the desired menu item. Basic commissioning In this menu, you can set the following parameters for the basic parameterization: Table 8-4 Drive Object VectorMV Parameter Parameter text p700[0] Macro binector input (BI) p1000[0] Macro connector inputs (CI) for speed setpoints p1070[0] CI: Main setpoint p1080[0] Minimum speed p1082[0] Maximum speed p1120[0] Ramp-function generator ramp-up time p1121[0] Ramp-function generator ramp-down time p1135[0] OFF3 ramp-down time Complete commissioning In this menu, all of the parameters of the basic parameterization except for the parameters of the DO B_Infeed can be set. 142 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Operation 8.2 Operation via the AOP30 operator panel Motor identification This function has not yet been implemented and will be made available at a later point in time. Resetting the fan runtime In this menu, you can reset the fan counter. The fan counter must be reset after a fan replacement. 1. Press the <> function key to select the "Reset runtime" row. 2. Confirm the selection with <OK>. The reset of the fan runtime also clears alarm A30042. 9(&725 B IDQRSHUDWLQJWLPH IDQRSHUDWLQJWLPH +RXUV 5HVHWIDQRSHUDWLQJWLPH +HOS 8.2.3.6 %DFN 2. Commissioning / Service - AOP settings Commissioning /Service / AOP settings menu structure 0DLQPHQX &RQWUROVHWWLQJV 'LVSOD\VHWWLQJV ,&RPPLVVLRQLQJ VHUYLFH $23 VHWWLQJV 'HILQHRSHUDWLRQVFUHHQ 6HWGDWHWLPH $GYDQFHGVHWWLQJV 5HVHW$23VHWWLQJV Figure 8-12 Commissioning /Service / AOP settings menu structure Calling up AOP settings 1. Press the <<MENU>> key. 2. Press the <> function key to select the "Commissioning/Service" row. Press the <OK> function key to confirm the selection. 3. Press the <> function key to select the "AOP settings" row. Press the <OK> function key to confirm the selection. 4. Press the or function key to select the desired setting. Press the <OK> function key to confirm the selection. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 143 Operation 8.2 Operation via the AOP30 operator panel * The "Extended settings" menu appears only when the "special access" access level is selected. Control settings In this menu, set the functions that the AOP control keys should perform. For example, you can specify whether the <OFF> key is associated with the OFF1, OFF2 or OFF3 function. More detailed information is available in Chapter "Control settings". Display settings Make the following AOP settings in this menu: Illumination (on, off after 2 minutes, off) Intensity of illumination Contrast 'LVSOD\VHWWLQJV /LJKWLQJ /LJKWLQJLQWHQVLW\ &RQWUDVW 21 %DFN &KDQJH 1. Select the desired setting using the <> function key. 2. Change the setting using the <Change> function key. 3. Confirm the setting using the <Back> function key. Defining the operation screen In this menu, you can define which parameters the operation screen should display. A DriveObject (DO) selection is offered on each display. The corresponding parameter list is offered for each DO. You can select and assign all parameters (r and p). In addition, a selection of plausible displayable parameters is displayed for each DO. More detailed information is available in Chapter "Defining operating screens". 144 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Operation 8.2 Operation via the AOP30 operator panel Setting the date/time In this menu, you can set the date and time. 6HWGDWHWLPH 'DWH WWPPMMMM 7LPH 66PPVV 6\QFKURQL]DWLRQ & 1RQH VDYH &DQFHO 1. Select the desired setting using the <> function key. 2. Change the setting using the numeric keys. You can delete incorrect entries using the < C> function key. 3. Select the "synchronization" row. Make the desired setting. - "None" The AOP time is managed internally and is displayed in the upper right of the operating screen. - "AOPDRIVE" The AOP time is recorded in the drive each time the AOP is powered up, and daily at 2:00 AM. If a valid synchronization is detected, the time stamp for faults and alarms is displayed on the AOP in real time. - "DRIVE AOP" This operating state requires that the drive be connected to and synchronized by a master clock. Every time the AOP is powered up, and daily at 2:00 AM, the time of the drive is adopted as the time of the AOP. If a valid synchronization is detected, the time stamp for faults and alarms is displayed on the AOP in real time. 4. Select "Save". Confirm the setting with <OK>. Extended settings In this menu, you can make the following extended settings: Load the AOP settings from the CU Automatically acknowledge topology SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 145 Operation 8.2 Operation via the AOP30 operator panel Mixed operation of servo/vector Database mode for the test bay $GYDQFHGVHWWLQJV 'RZQORDG$23VHWWLQJVIURP&8 $XWRPDFNQRZOHGJHWRSRORJ\ &RPELQHGRSHURI6(5929(&725 'DWDEDVHPRGHIRUWKHWHVWILHOG %DFN <HV <HV 1R 1R &KDQJH 1. Select the desired setting using the function key. 2. Change the setting using the <Change> function key. 3. Confirm the setting using the <Back> function key. Load the AOP settings from the CU Each time the power supply of the AOP is switched on, the AOP settings are read by the drive. This makes it possible to swap AOPs without losing the settings. If you set the selection to "No" in the "Load AOP settings from CU" row, you can transfer the settings from one drive to the other one. Automatically acknowledge topology If the AOP is connected to a drive that has not yet saved a setpoint topology (p99=r98), the topology is automatically acknowledged by the AOP. If the selection is set to "No" in the "Automatically acknowledge the topology" row, the automatic acknowledgement of the topology is disabled. Mixed operation of servo/vector This function is not supported. Database mode for the test bay If the AOP is connected to a drive unit with a changed topology or changed software version, the database is deleted and rebuilt. For the special device test application, you can activate the "Database mode for the test bay" function. This activation can be used, for example, to redefine a Motor Module as an Active Line Module during the test. The automatic deletion of the database is disabled. 146 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Operation 8.2 Operation via the AOP30 operator panel Resetting the AOP settings In this menu, you reset the following settings to their default setting: Language Display settings Operation screen Control settings $23(LQVWHOOXQJHQU3/4FNVHW ]HQ 5HVHW$23VHW WLQJV 6WHXHU XQJVHLQVWHOOXQJHQ <HV 'LVSOD\HLQVWHOOXQJHQ %HWULHEVPDVNHGHI LQLHUHQ 1R 'DWXP8KU ]HLWHLQVWHOOHQ $23(LQVWHOOXQJHQ]XU 3/4FNVHW ]HQ 2. 1. Press the <> function key to select the "Yes" or "No" setting. - "Yes: All settings that are different from the factory settings are reset immediately. The setting may cause the drive to switch to an unwanted operational states. - "No": The values are not reset 2. Confirm the setting with <OK>. The settings become active immediately. 8.2.3.7 Commissioning / Service - AOP diagnostics Commissioning / Service / AOP diagnostics menu structure 6RIWZDUHGDWDEDVHYHUVLRQ 0DLQPHQX %DWWHU\VWDWXV &RPPXQLFDWLRQ &RPPLVVLRQLQJ VHUYLFH $23 GLDJQRVWLFV .H\ERDUGWHVW /('WHVW Figure 8-13 )RUPDWIODVK)6 &OHDUSHUVLVWHQWGDWDEDVH Commissioning / Service / AOP diagnostics menu structure 1. Press the <<MENU>> key. 2. Press the <> function key to select the "Commissioning/Service" row. Press the <OK> function key to confirm the selection. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 147 Operation 8.2 Operation via the AOP30 operator panel 3. Press the <> function key to select the "AOP diagnostics" row. Press the <OK> function key to confirm the selection. 4. Press the <> or <> function key to select the desired setting. Press the <OK> function key to confirm the selection. * These menus appear only if the "Special access" access level was selected Software/database version 6RI W ZDUHGDWDEDVHYHUVLRQ 6HU LDOQXPEHU 7' 0/)%1R 6/ $ $ &$ )LU PZDUH 'DWHWLPH %DFN The following values are displayed: Serial number MLFB number Firmware Date/time Database Battery status This menu shows the charging state of the AOP battery. The battery ensures that the data in the database and the current time are retained. A battery voltage 3 V corresponds to 100% of the battery voltage. A battery voltage 2 V corresponds to the value 0%. The data is secure up to a battery voltage of 2 V. Depending on the battery voltage, the following messages are issued: Battery voltage 2.45 V: "Replace battery". Battery voltage 2.30 V: "Alarm, weak battery". 148 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Operation 8.2 Operation via the AOP30 operator panel Battery voltage 2.00 V: "Important: The battery is dead". If the drive is not activated for a long period of time, the time and status of the database might not be displayed. The missing information is caused by insufficient voltage of the battery. In this case, messages appear that prompt you to replace the battery, load the database and set the time. Information on replacing the battery can be found in the operating instructions of the drive in the "Maintenance and Servicing" section. %DW WHU \VWDWXV 9 %DWWHU\YROWDJH %DFN Communication The "Communication" menu represents the status of the communication between AOP30 and CU. The following items are displayed: Number of fault-free message frames Number of faulty message frames Number of character frame faults Number of overflow errors Number of start limiter errors Number of end limiter errors Number of character length errors Number of frame test mark errors Number of frame test mark errors Number of frame transfer errors Number of layer 2 message frame failures PPI status Number of layer 7 message frame failures Number of message frame repetitions (SD2) &RPPXQLF DWLRQ (UURUIUHHWHOHJUDPV 7HOHJUDPHUURU &KDUDFWHUIUDPHHUURU 3DULW\HUURU 2YHUIORZHUURU 6WDUWGHOLPLWHUHUURU SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 %DFN 149 Operation 8.2 Operation via the AOP30 operator panel Keyboard test Use this menu to test the function of each individual key of the AOP. Keys that you press are represented on a symbolic keyboard on the display. You can press the keys in any order you wish. If each key has been pressed at least once, you can exit the menu by pressing the <Back> key. You can also exit the "Keyboard test" menu by pressing and holding any key. LED test Use this menu to test the function of the AOP LEDs. Flash FS formatting The drive reads the ACX files to describe the parameters and alarms. The ACX files are buffered in the Flash File System. The data is deleted after being parsed. To rule out the risk of files being retained, the Flash File System can be manually deleted via this menu item. Note The Flash memory is formatted, without further confirmation, after pressing the <OK> function key. Note The CompactFlash card is not formatted. Delete persistent database The database with all parameter and alarm descriptions of the found topology is stored in the battery-buffered RAM. The database is available immediately after a power off and on of the supply voltage. The "Delete persistent database" menu item deletes the database manually. The database will be rebuilt during the next power up. Note The database is deleted immediately, without further confirmation, after pressing the <OK> function key. 150 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Operation 8.3 Parameter 8.2.3.8 Language Language menu structure 0DLQPHQX /DQJXDJH Figure 8-14 Language menu structure Selecting a language 1. Press the <MENU> key. 2. Press the <> function key to select the "Language" row. Press the <OK> function key to confirm the selection. 3. Press the <> function key to select the desired language. 4. Confirm with the <OK> function key. 8.3 Parameter 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. 8.3.1 Parameters The drive is adapted to the relevant drive task by means of parameters. Each parameter is identified by a unique parameter number and specific attributes. Such attributes are, for example: Readable attributes Writable attributes BICO attributes The parameters can be accessed via the following means: PC with commissioning tool via PROFIBUS Operator panel SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 151 Operation 8.3 Parameter 8.3.2 Parameter types Parameter types The following parameters are available: Adjustable parameters (write/read) Adjustable parameters directly influence the response of a function, e.g. the ramp-up and ramp-down time of a ramp-function generator. Visualization parameters (read-only) Display parameters are used to display internal variables, e.g. the actual motor current. 3DUDPHWHU UHDG U %,&2RXWSXW Figure 8-15 1RUPDOUHDG SDUDPHWHUV UHDGZULWH S %,&2LQSXW 1RUPDOUHDGZULWH SDUDPHWHUV Parameter types All these drive parameters can be read and changed via PROFIBUS using the mechanisms defined in the PROFIdrive profile. Parameter categories The parameters for the individual drive objects (DO) are categorized according to data sets as follows: Data-set-independent parameters These parameters exist only once per drive object. Data-set-dependent parameters These parameters can exist several times for each drive object and are addressed via the parameter index for reading and writing. The following data set types can be distinguished: - CDS: Command data set By parameterizing several command data sets and switching between them, the drive can be operated with different preconfigured signal sources. - DDS: Drive data set The drive data set contains the parameters required for switching the drive control parameters. The CDS and DDS data sets can be switched during operation. Further data set types also exist, however these can only be activated indirectly by means of a DDS changeover. - EDS: Encoder data set - MDS: Motor data set 152 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Operation 8.4 Functions 8.4 Functions 8.4.1 Setpoint channel and closed-loop control 8.4.1.1 Setpoint channel Setpoint addition Fine tuning (correction variable) often needs to be carried out on site for applications in which the command variables are generated by central control systems. You achieve the correction variable using the addition point for the main and additional setpoint in the setpoint channel. Both variables are imported simultaneously via two separate or one setpoint source and added in the setpoint channel. Adjustable parameters Parameter Setting p1070 Main setpoint p1071 Main setpoint scaling r1073 Main setpoint effective p1075 Supplementary setpoint p1076 Supplementary setpoint scaling r1077 Supplementary setpoint effective r1078 Total setpoint effective These parameters concern connector inputs to which the setpoint values are connected. Function diagram FP 3030 Direction reversal A reversal of the rotational direction is necessary under the following conditions: When the drive should be operated in both directions of rotation. If the cables were connected with an incorrect phase sequence. Note Note that only one direction of rotation is enabled in the factory setting. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 153 Operation 8.4 Functions To subsequently reverse the phase sequence, you must interchange the motor cables or enter a negative setpoint. A direction reversal cannot be achieved with parameter settings. Direction of rotation changeover is initiated as follows: Controlled via PROFIBUS using control word 1, bit 11 Controlled from the cabinet operator panel ("LOCAL mode" function) with the "direction of rotation changeover" key. Table 8-5 Parameter Parameter Setting p1110 Inhibit negative direction p1111 Inhibit positive direction p1113 Direction of rotation reversal For further information, see the function diagram 3040. Skip frequency bands and minimum speed Variable-speed drives can generate critical whirling speeds within the control range of the entire drive train. This prevents steady-state operation in their proximity, that is, the range of critical whirling speeds can still be passed through. The drive, however, must not remain here because this can cause excitation of the sympathetic oscillations. The suppression bandwidths allow this range to be blocked for steady-state operation. Because the points at which critical whirling speeds occur in a drive train can vary depending on age or thermal factors, a broader control range should be blocked. To ensure that the speed does not constantly increase and decrease in the suppression bandwidth (speeds), the bands are assigned a hysteresis. Specify a minimum speed in order to block a specific range around the stopped state for stationary operation. Table 8-6 Parameter Parameter Setting p1091 Suppression speed 1 p1092 Suppression speed 2 p1093 Suppression speed 3 p1094 Suppression speed 4 p1101 Suppression speed bandwidth p1080 Minimum speed r1112 Speed setpoint after minimum limiting You can find additional information in function diagrams 1550 and 3050. 154 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Operation 8.4 Functions Speed limitation The speed limitation is used to limit the maximum permitted speed for the complete drive train. The drive and the load machine / process are protected from damage caused by overspeed. Table 8-7 Parameter Parameter Setting p1082 Maximum speed, both directions of rotation p1083 Speed limit in positive direction of rotation p1086 Speed limit in negative direction of rotation You can find additional information in function diagrams 1550 and 3050. Ramp-function generator The ramp-function generator limits the rate at which the setpoint changes when the drive is accelerating or decelerating. This prevents excessive setpoint step changes from damaging the drive train. Parameter p1115 can be used to select two ramp-function generators. To improve the control properties with regard to load surges, set additional rounding times in the lower and upper speed range. The rounding times achieve the following: They protect mechanical components, such as shafts and couplings. The overshoot of the actual speed while approaching the setpoint is avoided. The control quality is improved. The ramp-up and ramp-down times each refer to the maximum speed (p1082). Note If rounding times are too long, this can cause the setpoint to be overshot if the setpoint is reduced abruptly during ramp-up. Rounding is also effective in the zero crossover; When the rotational direction is reversed, the ramp-function generator output is reduced to zero using the following parameters: The initial rounding The ramp-down time The final rounding The new inverted setpoint is approached using the following parameters: The initial rounding The ramp-up time The final rounding SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 155 Operation 8.4 Functions Rounding times that can be set separately are active in the event of a fast stop (OFF3). The actual ramp-up/ramp-down times increase with active rounding. Table 8-8 Parameter Parameter Setting P1115 Selection between simple ramp-function generator and extended ramp-function generator p1120 Ramp-function generator ramp-up time p1121 Ramp-function generator ramp-down time p1130 Ramp-function generator initial rounding-off time p1131 Ramp-function generator final rounding-off time p1135 OFF3 ramp-down time p1136 OFF3 initial rounding-off time p1137 OFF3 final rounding-off time Note The effective ramp-up time increases when you enter an initial and final rounding-off time. Effective ramp-up time = p1120 + (0.5 x p1130) + (0.5 x p1131) You can find additional information in function diagrams 3060 and 3070. 8.4.1.2 Vector control Properties of vector control Vector control has the following properties and features: Stability during load and setpoint changes. Improved control characteristic thanks to short rise times for setpoint changes. Improved disturbance characteristic thanks to short settling times for load changes. Acceleration and braking are possible with maximum available torque. Motor protection due to variable torque limitation in motor and regenerative mode. Drive and braking torque controlled independently of the speed. These benefits can even be achieved without speed feedback. Note Vector control can be used with or without an encoder. 156 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Operation 8.4 Functions Benefits of vector control with an encoder A speed encoder is only required in the following conditions: A separately excited motor is used. Highest speed accuracy is required. The most stringent demands on the dynamic response are required. Better command behavior is desired. The shortest possible settling times during disturbances are required. Torque control in a range greater than 1:10 is required. A defined and/or variable torque for speeds below approx. 5% of the rated motor frequency (p0310) must be maintained. Open-loop and closed-loop control methods (p1300): V/f control with linear characteristic. I/f control with fixed current. Speed control. Torque/current control (in short: torque control). Vector control with encoder Benefits of vector control with an encoder: The speed can be controlled right down to 0 Hz (standstill). Stable control response throughout the entire speed range. Allows a defined and/or variable torque for speeds below approx. 10% of the rated motor speed to be maintained. In comparison with speed control without an encoder, the dynamic response of drives with an encoder is significantly increased. The reason is that the speed is measured directly and used for the model formation of the current components. Function diagrams 1590 1610 6010 6030 6040 6050 6060 6490 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 157 Operation 8.4 Functions Vector control without an encoder Vector control without an encoder is used with induction motors. In vector control without an encoder, the position of the flux and actual speed must be determined via the electric motor model. The model is buffered by the incoming currents and voltages. At low frequencies (approx. 0 Hz), the model cannot determine the speed. For this reason and due to uncertainties in the model parameters or inaccurate measurements, the system is switched from closed-loop to open-loop operation in this range. The switchover is governed by time and frequency conditions (p1755, p1756, and p1758). If the setpoint frequency at the ramp-function generator input and the actual frequency are below p1755 x p1756 simultaneously, the system does not wait for the time condition. , IBDFW , S>PLQ@ S>PLQ@ S W 2SHQFRQWUROORRS &ORVHGFRQWURO Figure 8-16 W S Switchover conditions In open-loop operation, the actual speed value is the same as the setpoint value. To provide the resulting static or dynamic load torque for suspended loads or acceleration tasks, modify the following parameters: p1610 (constant torque increase) If p1610 is set to 0%, only the magnetizing current r0331 is impressed. For a value of 100%, the rated motor current p0305 is impressed. p1611 (torque increase) To ensure that the drive does not stall during acceleration, p1611 can be increased or acceleration pre-control for the speed controller used. The p1611 increase is also advisable to ensure that the motor is not subject to thermal overload at low speeds. Vector control without encoder has the following features in the low frequency range: Closed-loop operation up to approx. 1 Hz output frequency Start-up in closed-loop operation (directly after drive is energized) Passes through low frequency range (0 Hz) in closed-loop operation Note In this case, the speed setpoint upstream of the ramp-function generator must be greater than p1755. 158 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Operation 8.4 Functions Closed-loop operation above approx. 1 Hz (p1755) and the ability to start or reverse at 0 Hz directly in closed-loop operation (p1750) produce the following benefits: No switching action within the closed-loop control necessary. This means smooth behavior, no frequency drops. Stationary speed-torque control up to approx. 1 Hz. Note For controlled reversing or controlled starting for 0 Hz, under the following condition the closed-loop control is switched automatically from closed-loop controlled operation to openloop controlled operation: Dwell-time > 2 seconds or > p1758 in the range of 0 Hz 8.4.1.3 U/f control As an alternative to vector control, a U/f control is available for induction motors. This technique is only appropriate when there are no highly dynamic requirements, e.g. pumps and fan drives. V/f control aims to maintain a constant flux in the motor whereby the flux () is proportional to the magnetization current (I) and the ratio of voltage (V) to frequency (f). ~ I ~ V/f The torque (M) generated by the induction motors is, in turn, proportional to the vector product ( x I) of the flux and current. The V/f characteristic is derived from these basic premises: To generate as much torque as possible with a given current, the motor must function using the greatest possible constant flux. To maintain a constant flux (), therefore, the voltage must be changed in proportion to the frequency f. The voltage change ensures that a constant magnetization current I flows. 803 3RLQWRIPRWRU 83 0QQ 83 0 I 9ROWDJHUDQJH Figure 8-17 IQ )LHOGUDQJH IPD[ Operating areas and characteristic curves for the induction motor with drive supply Adjustable parameters Parameter Setting p1300 Open-loop/closed-loop operating mode / control type SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 159 Operation 8.4 Functions Function diagrams 1590 1690 5060 6300 Note A simple rise in voltage can be achieved with parameter p6890. Refer to function diagram 6300. 8.4.2 Analog and digital inputs/outputs 8.4.2.1 Analog outputs The customer terminal block is equipped with two analog outputs for outputting setpoints via current or voltage signals. Factory setting: AO0: Actual speed value 0 AO1: Actual motor current value 0 Adjustable parameters p4071 Analog outputs, signal source p4073 Analog outputs, smoothing time constant r4074 Analog outputs, actual output voltage/current p4076 Analog outputs, type p4077 Analog outputs, characteristic value x1 p4078 Analog outputs, characteristic value y1 p4079 Analog outputs, characteristic value x2 p4080 Analog outputs, characteristic value y2 Function diagrams 1840 9572 160 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Operation 8.4 Functions List of signals for the analog outputs Signal Parameter Unit Scaling (100% = ...) Speed setpoint for setpoint filter r0060 1/min p2000 Motor speed unsmoothed r0061 1/min p2000 Actual speed smoothed r0063 1/min p2000 Output frequency r0066 Hz Reference fre quency Output current r0068 Aeff p2002 DC-link voltage r0070 V p2001 Torque setpoint r0079 Nm p2003 Output power r0082 kW r2004 Control deviation r0064 1/min p2000 Slip frequency r0065 Hz Reference fre quency Phase current actual value r0069 A p2002 Control factor r0074 % Reference control factor Field-generating current setpoint r0075 A p2002 Field-generating actual current r0076 A p2002 Torque-generating current setpoint r0077 A p2002 Torque-generating actual current r0078 A p2002 Flux setpoint r0083 % Reference flux Actual flux r0084 % Reference flux DC-link voltage r0088 V p2001 Phase voltage r0089 V p2001 Speed controller output r1480 Nm p2003 I component of speed controller r1482 Nm p2003 For diagnostic purposes For further diagnostic purposes Scaling Variable Scaling parameter Default for quick commissioning Reference speed 100% = p2000 p2000 = Maximum speed (p1082) Reference voltage 100% = p2001 p2001 = 1000 V Reference current 100% = p2002 p2002 = Current limit (p0640) Reference torque 100% = p2003 p2003 = 2 x rated motor torque Reference power 100% = r2004 r2004 = (p2003 x p2000 x pi) / 30 Reference frequency 100 % = r2000 / 60 Reference control factor 100% = Maximum output voltage without overload Reference flux 100% = Rated motor flux Reference temperature 100% = 100 C SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 161 Operation 8.4 Functions Example: Changing analog output 0 from current to voltage output -/+ 10 V ; 9ROWDJHRXWSXWSUHVHQWDWWHUPLQDOJURXQGLVDWWHUPLQDO S 6HWDQDORJRXWSXWW\SHWR99 Figure 8-18 Example: Setting analog output 0 Example: Changing analog output 0 from current to voltage output - / +10 V and setting the characteristic ; S>@ S>@ S>@ S>@ S>@ Voltage output present at terminal 1, ground is at terminal 2 Set TM31.AO_type [analog output 0] to between -10 and +10 V. Set TM31.AO_char. x1 to 0.00%. Set TM31.AO_char. 1 to 0.000 V. Set TM31.AO_char. x2 to 100%. Set TM31.AO_char. y2 to 10.000 V. Factory setting 162 Digital output Terminal Factory setting DO0 X542: 2,3 "Pulses enabled" DO1 X542: 5,6 "No fault" DI/DO8 X541: 2 "Ready for switching on" DI/DO9 X541: 3 DI/DO10 X541: 4 DI/DO11 X541: 5 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Operation 8.4 Functions 8.4.2.2 Digital outputs The drive is equipped with four bidirectional digital outputs (terminal X541) and two relay outputs (terminal X542). These outputs are, for the most part, freely parameterizable. For details, please refer to the circuit manual of the drive. List of signals for the digital outputs Signal Bit in status word 1 Parameter 1 = Ready to switch on 0 r0889.0 1 = Ready to operate (DC link loaded, pulses blocked) 1 r0889.1 1 = Operation enabled (drive follows n_set) 2 r0889.2 1 = Fault present 3 r2139.3 0 = Coast to stop active (OFF2) 4 r0889.4 0 = Fast stop active (OFF3) 5 r0889.5 1 = Power-on disable 6 r0889.6 1 = Alarm present 7 r2139.7 1 = Speed setpoint/actual deviation in the tolerance bandwidth (p2163, p2166) 8 r2197.7 1 = Control required to PLC 9 r0899.9 1 = f or n comparison value reached or exceeded (p2141, p2142) 10 r2199.1 1 = I, M, or P limit reached (p0640, p1520, p1521) 11 r1407.7 Reserved 12 0 = Alarm motor overtemperature (A7910) 13 Reserved 14 0 = Alarm thermal overload in power unit (A5000) 15 r2129.14 r2129.15 1 = Pulses enabled (inverter is clocking, drive is carrying current) r0899.11 1 = n_act p2155 r2197.1 1 = n_act > p2155 r2197.2 1 = Ramp-up/ramp-down completed r2199.5 1 = n_act < p2161 (preferably as n_min or n=0 message) r2199.0 1 = Torque setpoint < p2174 r2198.10 1 = LOCAL mode active (control via operator panel) r0807.0 0 = Motor blocked r2198.6 1 = Ready to switch on SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 0 r0889.0 163 Operation 8.4 Functions 8.4.2.3 Digital inputs/outputs The TM15 modules are the interface with the system I/O. These modules are used to read the signals to the closed-loop controller. The signal status is indicated by a green LED on the front panel. The TM15 module is equipped with 24 floating digital inputs/outputs, which are divided into three groups of eight channels. Each group has a separate supply voltage connection [(L1+, M1), (L2+, M2), (L3+, M3)]. This enables signals to be processed with separate reference potentials. If a system supply voltage for monitoring signals is not available, the signal monitoring function can be supplied by the 2P24, which is protected with a circuitbreaker. In this case, the 0 V potential of the closed-loop controller is distributed in the system in a star configuration. If this concept is rigorously applied, it can eliminate the risk of ground loops. / ',3B WR ',3B 0 ',3B WR / ',3B 0 3 3 ,QVWUXPHQWD WLRQDQG FRQWURO 0RWRU 7UDQVIRUPHU 0 / ',3B WR ',3B 0 3 0 0 70 *URXS Figure 8-19 *URXS *URXS Potential supply of external signals Signals are transmitted via a conducted electrical interface, which can be affected by conducted interference. To minimize external interference, the signals are injected asymmetrically and are floating. When this transmission method is used, the receiver (optocoupler) receives the signal along with the reference potential from the transmitter. The signal data is, therefore, forwarded to an optocoupler (group) via a closed loop. The symmetrical interference is minimized by means of twisted cables (outgoing/incoming conductors). In general, the shield should be applied at both ends of the shield support bar. The digital outputs of the TM15 are continued short-circuit proof. The logical status of the outputs can be read back. 164 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Operation 8.4 Functions 70 *URXSV 3 0 0 7UDQVIRUPHU 0RWRU ,QVWUXPHQWDWLRQDQGFRQWURO Figure 8-20 Digital signal output to the system I/O Designation Voltage values Rated value for output voltage (DC) 24 V Output current per channel 0.5 A Cumulative current of outputs (per group) 8.4.2.4 To 40 C, max. 4A To 50 C, max. 3A To 60 C, max. 2A Additional settings for analog outputs Two signals are freely available for each TM31, which can be used to output the analog signals. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 165 Operation 8.4 Functions Additional setting parameters for analog output 0 (AO0) Parameter Value Adjustment range p4077[0] Analog outputs, characteristic value x1 -1000.00 to +1000.00% Factory setting: 0.00 % Setting for the x coordinate in % of the first point on the scaling characteristic. Parameter Value Adjustment range p4078[0] Analog outputs, characteristic value y1 -20.000 to +20.000 V or mA Factory setting: 0.000 mA Setting for the y coordinate in V or mA of the first point on the scaling characteristic. When analog output 0 is set as a voltage output (p4076[0] = 1 / 4) and terminals X522: 3,2 are used, the unit is V. When analog output 0 is set as a current output (p4356[0] = 0 / 2 / 3) and terminals X522: 1,2 are used, the unit is mA. Parameter Value Adjustment range p4079[0] Analog outputs, characteristic value x2 -1000.00 to +1000.00% Factory setting: 100.00 % Setting for the x coordinate in % of the second point on the scaling characteristic. Parameter Value Adjustment range p4080[0] y2 of the characteristic of the analog out -20.000 to +20.000 V or mA puts Factory setting: 20.000 mA Setting for the y coordinate in V or mA of the second point on the scaling characteristic. When analog output 0 is set as a voltage output (p4076[0] = 1 / 4) and terminals X522: 3,2 are used, the unit is V. When analog output 0 is set as a current output (p4356[0] = 0 / 2 / 3) and terminals X522: 1,2 are used, the unit is mA. Additional setting parameters for analog output 1 (AO1) Parameter Value Adjustment range p4077[1] Analog outputs, characteristic value x1 -1000.00 to +1000.00% Factory setting: 0.00 % Setting for the x coordinate in % of the first point on the scaling characteristic. 166 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Operation 8.4 Functions Parameter Value Adjustment range p4078[1] Analog outputs, characteristic value y1 -20.000 to +20.000 V or mA Factory setting: 0.000 mA Setting for the y coordinate in V or mA of the first point on the scaling characteristic. When analog output 1 is set as a voltage output (p4076[1] = 1 / 4) and terminals X522: 6,5 are used, the unit is V. When analog output 1 is set as a current output (p4356[1] = 0 / 2 / 3) and terminals X522: 4,5 are used, the unit is mA. Parameter Value Adjustment range p4079[1] Analog outputs, characteristic value x2 -1000.00 to +1000.00% Factory setting: 100.00 % Setting for the x coordinate in % of the second point on the scaling characteristic. Parameter Value Adjustment range p4080[1] y2 of the characteristic of the analog out -20.000 to +20.000 V or mA puts Factory setting: 20.000 mA Setting for the y coordinate in V or mA of the second point on the scaling characteristic. When analog output 1 is set as a voltage output (p4076[1] = 1 / 4) and terminals X522: 6,5 are used, the unit is V. When analog output 1 is set as a current output (p4356[1] = 0 / 2 / 3) and terminals X522: 4,5 are used, the unit is mA. Example: Changing analog output 0 from current to voltage output 10 V and setting the characteristic ; S>@ S>@ S>@ SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Voltage output present at terminal 1, ground is at terminal 2 Set TM31.AO_type [analog output 0] to between -10 and +10 V Set TM31.AO_char. x1 to 0.00 %. Set TM31.AO_char. y1 to 0.000 V. 167 Operation 8.4 Functions S>@ S>@ 8.4.2.5 Set TM31.AO_char. x2 to 100.00 %. Set TM31.AO_char. y2 to 10.000 V. Scaling the input signal of the analog inputs In addition to the expanded setting options of the analog inputs, a function for scaling the input signal is available. Adjustable parameters of the scaling Parameter Value Adjustment range p4057[0] Analog inputs, characteristic value x1 -20,000 to 20,000 V or mA Default settings: 0,000 mA Setting for the x coordinate in V or mA of the first point on the scaling characteristic. When analog input 0 is set as a voltage input (p4056 = 0 / 4) and switch S5.0 is set to "V", the unit is V. When analog input 0 is set as a current input (p4056 = 2 / 3 / 5) and switch S5.0 is set to "I", the unit is mA. Parameter Value Adjustment range p4058[0] Analog inputs, characteristic value y1 -1000.00 to 1000.00% Default settings: 0,0 % Setting for the y coordinate in % of the first point on the scaling characteristic. Parameter Value Adjustment range p4059[0] Analog inputs, characteristic value x2 -20,000 to 20,000 V or mA Default settings: 0.000 mA Setting for the x coordinate in V or mA of the first point on the scaling characteristic. When analog input 0 is set as a voltage input (p4056 = 0 / 4) and switch S5.0 is set to "V", the unit is V. When analog input 0 is set as a current input (p4056 = 2 / 3 / 5) and switch S5.0 is set to "I", the unit is mA. 168 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Operation 8.4 Functions Parameter Value Adjustment range p4060[0] Analog inputs, characteristic value y1 -1000.00 to 1000.00% Default settings: 100,00 % Setting for the y coordinate in % of the second point on the scaling characteristic. 8.4.3 Monitoring functions and protective functions 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. 8.4.3.1 Insulation 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 M 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. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 169 Operation 8.4 Functions The insulation resistance can be > 20 M 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 k = Signal 1 (alarm) Limit value 2: Insulation resistance < 100 k = 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. 8.4.3.2 Tripping of the circuit-breaker in case of undervoltage If a serious fault occurs (e.g. overload in the DC link), the drive is immediately disconnected from the power supply by means of the safety shutdown function. WARNING Residual voltages 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 unit. 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 19)". The shutdown of the circuit-breaker is triggered by a safety contactor combination. The plant-side circuit-breaker must be equipped with an undervoltage trip to ensure the wirebreak protection for the circuit-breaker OFF command. If a circuit-breaker OFF command is issued as a result of an overvoltage trip, the circuit-breaker is switched off so that it is fail-safe. 8.4.3.3 DC-link short-circuiter The short-circuiter is triggered if an overvoltage occurs due to a serious fault and it cannot be brought under control by opening the circuit-breaker and unlocking the pulse block of the machine. When the short-circuiter thyristors are triggered, the circuit-breaker is always deactivated. Once the thyristors have been triggered, an acknowledgement signal is output to the closedloop control system. Fiber-optic conductors are used to control gating of the thyristors and the acknowledgement signals. The short-circuiter is triggered by the Power Stack Adapter. 170 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Operation 8.4 Functions The resistors absorb the energy stored in the DC link and limit the current. In the event of false tripping, the torque surge for the machine, which is still rotating, is limited by the resistors. WARNING High voltage If the short-circuiter is defective, this can significantly increase the discharge time. High voltages cause death or serious injury if the safety instructions are not observed or if the equipment is handled improperly. Never use force to open the doors while the DC-link capacitors are discharging. Always observe the five safety rules in "Safety information/personnel protection" and in the drive documentation. 8.4.3.4 Vdc-max closed-loop control The vdc-max closed-loop control permits (restricted) braking operation of a drive with a diode supply to the DC link. During braking operation, the machine supplies power back to the DC link. Due to the configuration, however, a diode supply cannot supply this power back to the line. The vdc controller controls the supply of power back from the machine to compensate for losses from the drive system and prevent the DC link voltage from exceeding the maximum value. This avoids any fault shutdown caused by braking ramps that have been set too short. The drive stops controlled. The ramp-down times may increase as a result. Adjustable parameters Parameter Function Adjustment range p1240 Vdc_controller configuration 0 ... 3 Factory setting: 1 Setting for the controller configuration for the voltage DC link (vdc controller). Values: 0: Inhib Vdc ctrl 1: Enable vdc-max controller The vdc-max controller increases the ramp-down times automatically to keep the DC link voltage within the permissible limits. Parameter Function Unit p1242 Vdc_max_controller switch-on level V Display of the switch-on level of the vdc-max controller. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 171 Operation 8.4 Functions Parameter Function Adjustment range p1243 Vdc_max_controller dynamic factor 10 ... 200 % Factory setting: 100 % Setting for the dynamic factor of the vdc-max controller. 100% means that the following parameters are used in accordance with their initial settings. The use is based on a theoretical controller optimization. p1250, gain p1251, settling time p1252, derivative-action time If subsequent optimization is required, this can be set using the dynamic factor. In this case p1250, p1251, p1252 parameters are weighted with the dynamic factor p1243. Parameter Function Adjustment range p1250 Vdc_controller proportional gain 0.00 ... 10.00 Factory setting: 1.00 Display of the switch-on level of the vdc-max controller. Parameter Function Adjustment range p1251 Vdc_controller integral time 1 ... 1000 ms Factory setting: 40 ms Setting for the integral-action time of the vdc controller. The effective integral time can be determined using p1243. Parameter Function Adjustment range p1252 Vdc_controller derivative-action time 1 ... 1000 ms Factory setting: 1 ms Setting for the derivative-action time of the vdc controller. The active derivative-action time can be determined using p1243. Parameter Function Adjustment range p1254 Vdc_max_controller automatic ON level detection 1/0 Factory setting: 0 Activates/deactivates automatic sensing of the switch-on level for the Vdc-max controller. Values: 0: Automatic detection disabled. 1: Automatic acquisition enabled Settings Parameter p1240 functions as a release: 0: Controller inhibited 1: Controller enabled 172 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Operation 8.4 Functions You use p1242 to define the starting point of the vdc-max controller. The starting point is the maximum value of the DC link voltage that cannot be exceeded. If the DC link voltage is below the starting point, the controller remains inactive. The controller gain can be changed by means of p1250. The set ramp-down remains inactive while the vdc_max controller is active. The ramp-down time increases the more excess kinetic energy is stored in the drive train. 8.4.3.5 Speed monitoring with incremental encoder Permanent speed monitoring enables motor control without an encoder. You can upgrade with additional incremental encoders under the following conditions: When high-performance applications, such as bearing control, require a permanent speed control. For long-continuing applications with low speeds. 8.4.3.6 Controlled stop, EMERGENCY STOP category 1 The EMERGENCY OFF function for controlled shutdown stops the drive by means of a quick stop process along a deceleration ramp that must be parameterized. Note The drive is stopped during controlled deceleration without braking modules with only a very low % braking torque. Depending on the load machine, the ramp-down procedure may take a long time. Connections of the EMERGENCY STOP button Most of the contacts of the EMERGENCY STOP button are integrated in the control circuit of the circuit-breaker. The two remaining normally-closed contacts of the EMERGENCY STOP button are situated on the terminal block. EMERGENCY STOP button Where connected =.LA-S31:11-12 =.LA-S31:21-22 =.LA-X11:9-10 Circuit breaker con trol circuit =.LA-X11:5-6 =.LA-S31:51-52 EMERGENCY STOP customer =.LA-X51:1, 2 =.LA-S31:61-62 Excitation equipment =.LA-X51:3, 4 =.LA-S31:31-32 =.LA-X11:7-8 If jumpered STOP; if not jumpered EMERGENCY OFF (produces an instantaneous stop command on the circuit-breaker) Max. connectable cross-section: 4 mm (AWG 10) You will find further information in the section "Circuit book" in your operating instructions. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 173 Operation 8.5 Fault and system messages 8.5 Fault and system messages 8.5.1 External alarms and faults With the terminal blocks TM15/TM31, there are 24 terminals. With STARTER or SCOUT, you can select which predefined messages are displayed and which protection devices are to be triggered. The list of parameterized faults and alarms can be found in the List Manual in the "Faults and alarms" section. 8.5.2 Message from the grounding switch Switching statuses "MPGS safe ON" and "MPGS safe OFF". The switching status of the make-proof grounding switch is indicated to the sequencer (D435 or CU320) by the messages "MPGS safe ON" and "MPGS safe OFF" via a TM15 module. These messages are required for displaying the status and for interlocking the circuit-breaker. Enabling the drive The doors of the power unit are unlocked under the following conditions: The serial link of "Safe On messages". The potential-free contacts of the make-proof grounding switch. The enable signal of the closed-loop/open-loop controller unlocked. The enable signal of the closed-loop/open-loop controller is signaled when one of the following conditions is satisfied: When after grounding the drive, an insulation resistance near 0 is set. When the "Ground-fault monitoring (stator) fault status" signal has triggered. This concept ensures a high degree of protection against residual voltages. Check that the following prerequisites are satisfied before you switch on the drive: The doors are closed. The make-proof grounding switch is open. The insulation resistance is in the normal range. If these conditions are fulfilled, you can start the drive. Insulation monitoring The deployed insulation monitoring device has an external delete input. This input is interconnected in such a way that the fault messages are automatically acknowledged at the insulation monitoring device. 174 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Operation 8.5 Fault and system messages If the drive ground is removed, the insulation resistance changes from short-circuit to the system-specific setpoint. The fault message is acknowledged. 8.5.3 Diagnosis 8.5.3.1 Indicating and rectifying faults 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). SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 175 Operation 8.5 Fault and system messages 8.5.3.2 Diagnostics via LEDs Behavior of the LEDs during booting The different statuses while booting are indicated using LEDs on the Control Unit. The duration of the individual statuses varies. If an error occurs, the booting procedure is terminated and the cause is indicated accordingly via the LEDs. Once the unit has been successfully booted, all the LEDs are switched off briefly. Once the unit has been booted, the LEDs are driven via the loaded software. LEDs of the Power Stack Adapters Table 8-9 LEDs of the Power Stack Adapters LED Color Status Description; cause Remedy PWR - Off 24 V power supply has failed or is too low (< 14 V) or internal fuse defective. Check input voltage. Continuous light 24 V power supply is available (>14 V); internal board voltage fault. Check input voltage. Continuous light 24 V power supply OK. -- - Off The electronic power supply is missing or lies outside the permissible tolerance range. - Green Continuous light The component is ready for operation and cyclic DRIVE-CLiQ communication is in progress. - Orange Continuous light DRIVE-CLiQ communication is being es tablished. Red Continuous light At least one fault is present in the com ponent. Red Green RUN / ERR If input voltage is > 18 V and LED off: Return component for repair. If input voltage is > 18 V and LED red: Return component for repair. Internal board voltages OK. Remedy and acknowledge fault. LED is controlled irrespective of the cor responding messages being reconfig ured. Green/red Green/or ange or Red/orange 176 0.5 Hz flashing light Firmware download in progress. - 2 Hz flashing light Firmware download is complete. Waiting for POWER ON. Carry out a POWER ON. Flashing light Component recognition via LED is acti vated. - The color depends on the LED state when component recognition is activated. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Operation 8.5 Fault and system messages LEDs of the DM10 diagnostics module The LEDS installed on the diagnosis module indicate the logic state of the signals present between the communication partners of the DM10 diagnosis module. Table 8-10 LED LEDs of the DM10 diagnostics module Communication partner Meaning: signal 1 / signal 0 H30 -X232/-X32 Control signals from PSA present / not present H31 -X232/-X32 Control signals from PSA present / not present H32 -X232/-X32 Control signals from PSA present / not present H33 -X232/-X32 Control signals from PSA present / not present H34 -X33/-X5 Binary plant signals for diagnosis on PADU8 present / not present H35 -X33/-X5 Binary plant signals for diagnosis on PADU8 present / not present H36 -X33/-X5 Binary plant signals for diagnosis on PADU8 present / not present H37 -X33/-X5 Binary plant signals for diagnosis on PADU8 present / not present H20 -X34/-X36 Internal power supply 1P24 OK / not OK H21 -X34/-X36 Internal power supply 1N24 OK / not OK H22 -X35/-X36 External power supply 2P24_1 and 2P24_2 OK / 2P24_1 or 2P24_2 not OK H23 - 8.5.3.3 Internal and external power supplies OK / not OK Diagnostics via parameters Diagnostic parameters for the device status r0002 Drive status Display of drive status r0046 Missing enable signals Display of the missing enable signals that are preventing the drive control from being commissioned Bit Signal name 0-signal 1-signal 00 OFF1 enable missing No Yes 01 OFF2 enable missing No Yes 02 OFF3 enable missing No Yes 03 Enable run missing No Yes 05 External power-on inhibit active No Yes 06 Commissioning not yet complete No Yes 09 Infeed enable missing No Yes 10 Ramp-function generator enable missing No Yes 11t No start ramp-function generator No Yes 12t No setpoint enable No Yes 16 OFF1 internal enable missing No Yes 17 OFF2 internal enable missing No Yes SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 177 Operation 8.5 Fault and system messages r0046 Missing enable signals Display of the missing enable signals that are preventing the drive control from being commissioned Bit Signal name 0-signal 1-signal 18 OFF3 internal enable missing No Yes 26 Drive inactive or not operational No Yes r0050 Active command data set (CDS) Display of the active command data set (Command Data Set, CDS) Bit Signal name 0-signal 1-signal 00 CDS effective, bit 0 No Yes 01 CDS effective, bit 1 No Yes 02 CDS effective, bit 2 No Yes 03 CDS effective, bit 3 No Yes Further notes can be found in the parameter description of the p0810, p0811, p0812, p0813 and r0836 parameters in the List Manual. The command data set selected via binector inputs p0810, p0811, p0812 and p0813 is displayed via r0836. Diagnostic parameters for digital inputs/outputs r0721 CU digital inputs terminal actual value Display of the actual value on the digital inputs Bit Signal name 0-signal 1-signal 00 DI 0 (X122.1) Low High 01 DI 1 (X122.2) Low High 02 DI 2 (X122.3) Low High 03 DI 3 (X122.4) Low High 04 DI 4 (X132.1) Low High 05 DI 5 (X132.2) Low High 06 DI 6 (X132.3) Low High 07 DI 7 (X132.4) Low High 08 DI/DO 8 (X122.7) Low High 09 DI/DO 9 (X122.8) Low High 10 DI/DO 10 (X122.10) Low High 11 DI/DO 11 (X122.11) Low High 12 DI/DO 12 (X132.7) Low High 13 DI/DO 13 (X132.8) Low High 14 DI/DO 14 (X132.10) Low High 15 DI/DO 15 (X132.11) Low High If a DI/DO is parameterized as output (p0728.x = 1), then r0721.x = 0 is displayed. DI: Digital input DI/DO: Bidirectional digital input/output 178 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Operation 8.5 Fault and system messages r0747 CU digital outputs status Display of the digital output status Bit Signal name 0-signal 1-signal 08 DI/DO 8 (X122.7) Low High 09 DI/DO 9 (X122.8) Low High 10 DI/DO 10 (X122.10) Low High 11 DI/DO 11 (X122.11) Low High 12 DI/DO 12 (X132.7) Low High 13 DI/DO 13 (X132.8) Low High 14 DI/DO 14 (X132.10) Low High 15 DI/DO 15 (X132.11) Low High Inversion via p0748 is taken into account. It does matter whether DI/DO is set as an input or output (p0728). DI/DO: Bidirectional digital input/output r4022 TM31 digital inputs status Display of the digital input status on the Terminal Module 31 (TM31) Bit Signal name 0-signal 1-signal 00 DI 0 (X520.1) Low High 01 DI 1 (X520.2) Low High 02 DI 2 (X520.3) Low High 03 DI 3 (X520.4) Low High 04 DI 4 (X530.1) Low High 05 DI 5 (X530.2) Low High 06 DI 6 (X530.3) Low High 07 DI 7 (X530.4) Low High 08 DI/DO 8 (X541.2) Low High 09 DI/DO 9 (X541.3) Low High 10 DI/DO 10 (X541.4) Low High 11 DI/DO 11 (X541.5) Low High DI: Digital input DI/DO: Bidirectional digital input/output r4047 TM31 digital outputs status Display of the digital output status on the Terminal Module 31 (TM31) Bit Signal name 0-signal 1-signal 00 DO 0 (X542.1 - 3) Low High 01 DO 1 (X542.4 - 6) Low High 08 DI/DO 8 (X541.2) Low High 09 DI/DO 9 (X541.3) Low High 10 DI/DO 10 (X541.4) Low High SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 179 Operation 8.5 Fault and system messages r4047 TM31 digital outputs status Display of the digital output status on the Terminal Module 31 (TM31) Bit Signal name 0-signal 1-signal 11 DI/DO 11 (X541.5) Low High Inversion via p4048 is taken into account. It does matter whether DI/DO is set as an input or output (p4028). DO: Digital output DI/DO: Bidirectional digital input/output r4022 TM15 digital inputs status Display of the digital input status on the Terminal Module 15 (TM15) Bit Signal name 0-signal 1-signal 00 DI/DO 0 (X520.2) Low High 01 DI/DO 1 (X520.3) Low High 02 DI/DO 2 (X520.4) Low High 03 DI/DO 3 (X520.5) Low High 04 DI/DO 4 (X520.6) Low High 05 DI/DO 5 (X520.7) Low High 06 DI/DO 6 (X520.8) Low High 07 DI/DO 7 (X520.9) Low High 08 DI/DO 8 (X521.2) Low High 09 DI/DO 9 (X521.3) Low High 10 DI/DO 10 (X521.4) Low High 11 DI/DO 11 (X521.5) Low High 12 DI/DO 12 (X521.6) Low High 13 DI/DO 13 (X521.7) Low High 14 DI/DO 14 (X521.8) Low High 15 DI/DO 15 (X521.9) Low High 16 DI/DO 16 (X522.2) Low High 17 DI/DO 17 (X522.3) Low High 18 DI/DO 18 (X522.4) Low High 19 DI/DO 19 (X522.5) Low High 20 DI/DO 20 (X522.6) Low High 21 DI/DO 21 (X522.7) Low High 22 DI/DO 22 (X522.8) Low High 23 DI/DO 23 (X522.9) Low High DI/DO: Bidirectional digital input/output r4047 TM15 digital outputs status Display of the digital output status on the Terminal Module 15 (TM15) Bit Signal name 0-signal 1-signal 00 DI/DO 0 (X520.2) Low High 01 DI/DO 1 (X520.3) Low High 02 DI/DO 2 (X520.4) Low High 180 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Operation 8.5 Fault and system messages r4047 TM15 digital outputs status Display of the digital output status on the Terminal Module 15 (TM15) Bit Signal name 0-signal 1-signal 03 DI/DO 3 (X520.5) Low High 04 DI/DO 4 (X520.6) Low High 05 DI/DO 5 (X520.7) Low High 06 DI/DO 6 (X520.8) Low High 07 DI/DO 7 (X520.9) Low High 08 DI/DO 8 (X521.2) Low High 09 DI/DO 9 (X521.3) Low High 10 DI/DO 10 (X521.4) Low High 11 DI/DO 11 (X521.5) Low High 12 DI/DO 12 (X521.6) Low High 13 DI/DO 13 (X521.7) Low High 14 DI/DO 14 (X521.8) Low High 15 DI/DO 15 (X521.9) Low High 16 DI/DO 16 (X522.2) Low High 17 DI/DO 17 (X522.3) Low High 18 DI/DO 18 (X522.4) Low High 19 DI/DO 19 (X522.5) Low High 20 DI/DO 20 (X522.6) Low High 21 DI/DO 21 (X522.7) Low High 22 DI/DO 22 (X522.8) Low High 23 DI/DO 23 (X522.9) Low High It does matter whether DI/DO is set as an input or output (p4028). DI/DO: Bidirectional digital input/output SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 181 Operation 8.5 Fault and system messages 182 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 9 Maintenance 9.1 Safety instructions for maintenance 9.1.1 High snubber circuit capacitor voltages WARNING High snubber circuit capacitor voltages The snubber circuit capacitors are not equipped with discharge resistors. The energy stored in the capacitors is discharged via a snubber resistor and the diodes. If the connection to the capacitor is interrupted, high voltages up to several 1000 V can result and cause an electric shock. This can result in death, severe injuries and significant material damage. You must always handle the capacitors as if they are charged. Discharge the snubber circuit capacitors. Short-circuit the snubber circuit capacitors briefly before you begin work on the converter. Observe Chapter, "Safety instructions" when carrying out any work at the converter. WARNING Improper maintenance and repairs Improper repairs can result in death and serious physical injury. Only qualified maintenance and installation personnel may perform repairs. WARNING Defective seals When working on the device, seals at the doors, roof panels as well as front, rear and side panels can be damaged. Operating the device with defective seals can result in death, serious injury or material damage. Replace the defective seals before commissioning. Observe the environmental conditions stated in the technical data. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 183 Maintenance 9.1 Safety instructions for maintenance WARNING High voltages from external supplies Magnetizing and demagnetizing equipment that is fed from an external voltage source can cause high voltages on the drive. This voltage can result in death or serious injury. Ensure that no voltage from external feeds exists before commencing maintenance and repair work. WARNING High voltage when the anti-condensation heating is operational The anti-condensation heating system is used when the drive is switched off due to production downtime or maintenance. For this reason, the heating is supplied with voltage from a separate line supply. When the supply voltage for the anti-condensation heating is connected, dangerous voltages are present in the cabinet unit, even with EMERGENCY OFF or when the main switch is open. This voltage can cause serious injury. The five safety rules must be observed. WARNING Hot anti-condensation heating surface When the temperature control limit value is reached the anti-condensation heating is switched on. Once activated, the anti-condensation heating can generate a great deal of heat. Contact can result in serious injury, such as skin burns. Ensure that the anti-condensation heating cannot be touched. Ensure that the anti-condensation heating is switched off before carrying out any repair or maintenance work. CAUTION Risk of falling When climbing onto the cover of the anti-condensation heating there is a risk of injury. Therefore, do not use the anti-condensation heating system to help you get to the top of the cabinet. 184 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Maintenance 9.1 Safety instructions for maintenance NOTICE Non-approved spare parts Using non-approved spare parts can affect the function of the equipment and damage it. Thirdparty spare parts and unapproved spare parts may not meet the requirements. Therefore, only use spare parts that have been approved by the manufacturer. NOTICE Foreign bodies in the drive If, after installation and maintenance work, foreign bodies are left in the drive, this can damage it when switching on. Before switching on, check as to whether there are any foreign bodies in the drive. Remove any foreign bodies. NOTICE Contamination Contamination and dirt can damage the device. Visually inspect the equipment at least once per year. For more information, please refer to the section "Visual inspections". Dust deposits inside the cabinet unit must be removed at regular intervals (or at least once a year) by qualified personnel in line with the relevant safety regulations. Note The actual intervals at which maintenance procedures are to be performed depend on the environmental and operating conditions. Define maintenance intervals for the drive which reflect your plant-specific environmental and operating conditions and meet your availability requirements. When doing so, take the prescribed maintenance intervals into consideration, as well as the instructions for repairing and replacing installed components. 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. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 185 Maintenance 9.2 Grounding the system 9.2 Grounding the system WARNING High voltage after shutdown High voltages are still present in the drive even after it has been shut down. Touching the drive can result in death or serious injury. Only work on the power unit if it has been sufficiently grounded. Before touching the drive, ensure that the following parts of the power unit are de-energized: Internal busbars Input and output terminals Auxiliary power supply Always observe the five safety rules (Page 19)when carrying out any work on the device. 9.2.1 Grounding with a grounding device Use a three-pole grounding harness for fixed ball points to ground the system. Note Ordering a grounding harness You can order the grounding harness. Contact the Service Center. Note Number of grounding harnesses Depending on the configuration of the drive, use a sufficient number of grounding harnasses. A grounding harness is required for each three-phase system. 186 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Maintenance 9.2 Grounding the system Attaching the grounding spider Secure the terminals of the grounding spider, first on the lower ball button , and then on the upper ball buttons . Ball head in the cabinet Figure 9-1 Ball buttons in the motor cabinet Grounding points SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 187 Maintenance 9.2 Grounding the system Attaching the grounding spider Figure 9-2 9.2.2 Example: Attaching the grounding spider Grounding using a make-proof grounding switch The drive is equipped with a make-proof grounding switch (in compliance with the requirements of IEC61800-5-1, Section 4.2.13). You can close the make-proof grounding switch when the doors are closed and only at a voltage below 60 V. If the auxiliary voltage fails completely, the make-proof grounding switch cannot be closed. It is not permissible that you open the doors before the make-proof grounding switch is closed. WARNING DC-link short-circuit A DC-link short-circuit can occur if grounding under voltage. This can cause injury and material damage. Remove the socket wrench before switching on. This activates the interlocking. 188 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Maintenance 9.3 Opening the doors To close the make-proof grounding switch, proceed as follows: 1. Take the socket wrench found in the tool set. 2. Turn the socket wrench in the counterclockwise direction. The contacts are closed and the DC-link voltage is grounded. Figure 9-3 9.3 Make-proof-grounding switch closed Opening the doors The drive is equipped with a door interlocking system. Depending on the design, this is an electromechanical door interlocking system or optionally a safety locking system. The door of the closed-loop control cabinet is not electromechanically interlocked. For this reason, it can also be opened during operation. 9.3.1 Opening the power unit doors for maintenance work Opening the doors of the power unit The doors can only be opened under the following conditions: The DC-link voltage is below a threshold value of 60 V. The circuit-breaker is open. The make-proof grounding switch is closed. The make-proof grounding switch is enabled by the software. With synchronous motors, the field contactor must return the external enable signal at the input with the status "OFF". SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 189 Maintenance 9.3 Opening the doors The position of the grounding switch lever is linked with the check-back signal for the status of the "Opened" power system breaker and the threshold value (V<Vlimit). WARNING High voltages High voltages can cause death or serious injury if safety rules are not observed or if equipment is handled improperly. Even when the door interlocking is released, dangerous high voltages can still be present at the auxiliary circuits (fans, anti-condensation heating, closed-loop control, etc.). Make sure that work is only carried out by qualified personnel under due observance of the five safety rules, the warning information in these operating instructions, and the safety information on the product itself. WARNING Not activated door lock If the door locking mechanism is not activated during operation, then the drive can be grounded live and cause a short-circuit in the DC link. A DC-link short-circuit can result in death, serious injury, or material damage. Remove the grounding bar before the voltage is switched on. This then activates the mechanical interlocking system, guaranteeing safe drive operation. 9.3.2 Manually unlocking power unit doors If the auxiliary voltage fails, you can only unlock the doors manually. To unlock the doors, proceed as described in the chapter titled "Preparation for use". See also Opening doors in preparation for use (Page 81) 190 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Maintenance 9.3 Opening the doors 9.3.3 Secure locking system (option M10) The doors are protected by a key transfer system. Figure 9-4 Principle of the mechanical door interlock Circuit-breaker Coded key for the key transfer unit Key transfer unit Coded key for cabinet doors Locks for the cabinet doors Figure 9-5 Components of the secure locking system SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 191 Maintenance 9.4 Preventive maintenance Operation 1. Switch off the circuit-breaker . Only now can you remove the coded key for the key transfer unit . 2. Use the key to unlock the keys in the key transfer unit . 3. Remove the keys and release the locks on the cabinet doors. Note The circuit-breaker cannot be closed again until the keys have been returned to the key transfer unit, the key transfer unit has been locked, and the coded key is back in the circuit-breaker. See also Safety locking system (option M10) (Page 67) 9.4 Preventive maintenance 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 environmental conditions at the location of use. The following servicing and inspection instructions are used as the basis for regular inspection of the equipment. 9.4.2 Checklist for preventive maintenance work Maintenance Carried out by: Clean the cabinet (exterior) Operator Clean the cabinet (interior) Check the electrical con nections (external power and test connections) and check the cable/screw ter minals. Siemens serv ice personnel Operator Frequency Comments As required Visual check, clean if required. Annually Visual check, clean if required. After 1 year Check the cable and screw termi nals regularly to ensure that they and then every 4 years. are secure. Tighten them if nec essary. Check the internal connec tions. Siemens serv ice personnel After 1 year Carry out inspection and visual check. Siemens serv ice personnel Annually 192 and then every 4 years. Refer to the following pages SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Maintenance 9.4 Preventive maintenance Maintenance Carried out by: Frequency Replace the water soften er / ion exchanger Operator When required (but af ter a maximum of two years). Replace the microfilter. Operator When the water soften er is replaced. Clean the sieve Comments As required Check the software. Siemens serv ice personnel Whenever parameters are changed Test the insulation (test mode for the Bender insula tion measuring device) Siemens serv ice personnel Every two years Inspect the motor and trans former. Siemens serv ice personnel See the applicable servicing instructions See the specifications in the op erating manual. Check the spare parts. Siemens serv ice personnel Annually If necessary reorder spare parts and then every 5 years. 9.4.3 Visual inspections 9.4.3.1 Equipment for visual inspections You require the following basic equipment to carry out the visual checks and maintenance work: Mirror Flashlight Torque wrench for tightening screws NOTICE Contamination Contamination and dirt can damage the device. Visually inspect the equipment at least once per year. For more information, please refer to the section "Visual inspections". Dust deposits inside the cabinet unit must be removed at regular intervals (or at least once a year) by qualified personnel in line with the relevant safety regulations. Note The actual intervals at which maintenance procedures are to be performed depend on the environmental and operating conditions. Define maintenance intervals for the drive which reflect your plant-specific environmental and operating conditions and meet your availability requirements. When doing so, take the prescribed maintenance intervals into consideration, as well as the instructions for repairing and replacing installed components. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 193 Maintenance 9.5 Maintenance 9.4.3.2 Checking the isolating clearances Slight, dry, non-conducting contamination is permitted. Remove contamination caused by dust in conjunction with high humidity. 9.4.3.3 Checking hoisting solenoids and security bolts Check the hoisting solenoids and security bolts at regular intervals. Replace defective hoisting solenoids and security bolts before (re)commissioning. 9.4.3.4 Checking the plug connections. Regularly check the plug connections to ensure they are seated correctly and the contacts are not corroded. Note The fiber-optic cables for the gating boards must be properly inserted in the connectors. 9.4.3.5 Checking the cable and screw terminals Check the cable and screw terminals regularly to ensure that they are secure. Tighten the screws if necessary. When doing this, comply with the specified torques (Page 201). Check the cabling for defects. Replace any defective parts immediately. 9.5 Maintenance 9.5.1 Fan maintenance CAUTION Temperature-controlled rotating fan If the converter is equipped with a temperature-controlled fan, the fan can run on even if the power section is switched off. You can be injured if you touch the fan. Wait until the fan has shut down. 194 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Maintenance 9.5 Maintenance 9.5.2 Filter mats 9.5.2.1 Replacing filter mats NOTICE Suction of the running cabinet fans Dust can enter the interior of the cabinet during filter mat replacement due to the suction of the running cabinet fans. Dust deposits can damage the device. Ensure that no dust enters the cabinet when replacing the filter mats. 1. Remove the screws for the louvered fan grid in the cabinet door. Figure 9-6 Schematic diagram: Replacing filter mats 2. Remove the filter mat. 3. If there is a slight amount of dirt, clean the filter mat at a suitable location. Depending on the degree of pollution, you can also clean the filter mats using a vacuum cleaner. If the filter mat is damaged, or the frequency of alarms increases, dispose of the dirty filter mat in the correct fashion. Use a new filter mat. 4. Insert the filter mat in the frame of the fan opening. In order that dirt is not drawn into the converter, insert a clean mat in the same direction as it was installed before the cleaning. 5. Carefully place the louvered cover over the frame. 6. Retighten the cover screws. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 195 Maintenance 9.5 Maintenance 9.5.2.2 Replacing the filter mats in the roof assembly NOTICE Suction of the running fans Dust can enter the interior of the cabinet during filter mat replacement due to the suction of the running fans. Dust deposits can damage the device. Ensure that no dust enters the cabinet when replacing the filter mats. Figure 9-7 Changing the filter in the roof assembly 1. Release the four screws . 2. Release the two screws . Remove the filter frame. 3. Remove the filter . If there is a slight amount of dirt, clean the filter mat at a suitable location. Depending on the degree of pollution, you can also clean the filter mats using a vacuum cleaner. If the filter mat is damaged, or the frequency of alarms increases, dispose of the dirty filter mat in the correct fashion. Use a new filter mat 4. Place a new filter in the frame . 5. Reattach the frame of the filter and cover. 196 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Maintenance 9.5 Maintenance 9.5.3 Replacing the back-up battery of the AOP30 operator panel Table 9-1 Technical specifications of the backup battery Type CR2032 3V lithium battery Manufacturer Maxell, Sony, Panasonic Nominal capacity 220 mAh Maximum permissible charging current 10 mA, limited to < 2 mA in the operator panel Self-discharge at 20 C 1%/year Service life in the backup mode > 1 year at 70 C; >1.5 years at 20 C Service life in operation > 2 years Replacing the backup battery 1. Switch off the main circuit-breaker. 2. Open the cabinet. 3. Disconnect the 24 VDC power supply and communications line on the operator panel. 4. Open the cover of the battery compartment. 5. Remove the old battery. 6. Insert a new battery. 7. Close the cover of the battery compartment. 8. Reconnect the 24 VDC power supply and communications line. 9. Close the cabinet. Note To ensure that no data is lost during a battery replacement, it must be replaced within one minute. If the time is exceeded, the AOP settings and input screen texts are reloaded from the CompactFlash card by a restart of the AOP with a connection to the drive. Set the clock to the new time. Figure 9-8 Replacing the backup battery SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 197 Maintenance 9.5 Maintenance Note Dispose of the battery in accordance with the applicable country-specific laws and regulations. Set date and time 1. Using the "MENU" key, select the main menu of the AOP 30. 2. Using "F2", select the menu item "Commissioning/service". Confirm with "F5" 3. Using "F2", select the menu item "AOP30 settings". Confirm with "F5" 4. Using "F2", select the menu item "Set date/time". Confirm with "F5". Using "F2", select the appropriate input location for date or time. Enter the actual value using the numerical keys. 5. Use "F5" to save the settings. 9.5.4 Load operator panel firmware, parameter and signal descriptions As of software version V2.4, the following data is stored on the CompactFlash card of the drive: The AOP firmware The parameter and signal descriptions All operator panel languages The new software version is detected during the initial activation of the AOP on a drive. The following data is displayed: Firmware being loaded Yes: Vxx.xx.xx (new software version) No: Vxx.xx.xx (currently loaded software version) Press the "F5" key ("Yes") on the AOP to confirm the selection of the new software version . The firmware will be loaded. This procedure takes approx. five minutes. Note While loading, do not switch off the power supply for the drive and AOP. If the loading process for the new firmware is not completed successfully because of a a power outage or the connection process, the currently loaded firmware is retained. The prompt appears at the next switch on. If a power outage or aborted connection occurs during the last 20 seconds of the loading process, the AOP firmware is destroyed. In this case, reload the firmware from the product CD via the PC with "LOAD_AOP30". 198 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Maintenance 9.6 Cleaning Reloading the firmware 1. Establish the RS232 connection from the PC to the AOP30. 2. Switch on the 24 V power supply. 3. On the PC, launch the LOAD_AOP30 program. 4. Choose the PC interface (COM1, COM2). 5. Choose the firmware (AOP30.H86) and open the file. 6. Follow the instructions in the program status window. Switch on the AOP30 using the red button (O). Loading begins. 9.6 Cleaning 9.6.1 Removing dust deposits Remove dust deposits at least once per year. You can use an ESD brush or an ESD vacuum cleaner. The ventilation openings in the cabinet must never be obstructed. NOTICE Cleaning fiber-optic cables and electronic components with a damp rag Fiber-optic cables, fiber-optic cable bundles and electronic components can be damaged if cleaned using a damp rag. If the components are very dusty, remove the dust using a dry, lint-free cloth. In so doing, do not bend the fiber-optic cables. NOTICE Material damage caused by aggressive cleaning agents Aggressive chemical agents can damage the electronics. This can cause the converter to malfunction. Never use any type of chemical agent or liquid. Only clean a very dirty converter after first discussing the situation 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). SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 199 Maintenance 9.7 Repairs 9.6.2 Cleaning aluminum parts The surface of untreated aluminum is always covered by a thin but dense oxide skin. The affinity of aluminum to oxygen is sufficiently strong that if the oxide skin is scratched, the metal reacts immediately with oxygen in the air. This forms a new oxide skin. This natural oxide layer acts as surface protection and is the reason for the good weathering resistance of aluminum materials. In most cases, this means that additional protective measures are superfluous. Remove very greasy layers using ethyl alcohol. If there are other heavily polluted areas, use ESD-compliant fiber or plastic brushes to clean them. NOTICE Unsuitable cleaning chemicals for aluminum Any strongly alkaline chemicals such as caustic potash or soda as well as acids corrode the aluminum and roughen the surface. The agents often recommended for cleaning glass also exhibit this effect and must therefore not be used on aluminum. Only use cleaning agents that are suitable for aluminum. NOTICE Unsuitable cleaning utensils for aluminum The use of unsuitable cleaning cloths and brushes may transfer metallic, corrosion-inducing impurities onto the aluminum. This can result in corrosion damage. Use ESD-compliant brushes and cloths. Do not use cleaning cloths and brushes that have been treated with copper, brass, bronze or other heavy metals. Use neither brass, bronze, or steel-wire brushes nor cloths or steel wool interwoven with copper wire. 9.7 Repairs WARNING Insufficient cable insulation Improperly laid or damaged cables and incorrectly attached cable shieldings can heat up in places and cause fires or short-circuits wherever they make contact. Check whether all the cable shields are intact. Insulate damaged cable shields. Make sure that a short-circuit cannot occur on the power cables due to failure of the insulation as a result of incorrect cable installation. 200 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Maintenance 9.7 Repairs NOTICE Drive failure When the auxiliary power supply is switched off, data about error message statuses can be lost. Inadequate diagnostic and error rectification measures can result in damage to the drive. We recommend using an uninterruptible power supply (UPS). If you are unsure of the measures necessary after the drive fails, or if a fault cannot be rectified, contact the Service Center. Note Fastening the cable ducts After performing repairs, refasten all cable ducts whose cover faces downward with a cable tie. The cable ties must be located at the same positions as in the delivered state. You will find more information in "Fastening the cable ducts with cable ties (Page 108)". Note Special investigation of defective components You can return defective components, e.g. phase modules, PowerCards, etc. for a special investigation. You can find more information here (http://support.automation.siemens.com/ WW/llisapi.dll?aktprim=1&lang=en&referer=%2fWW %2f&func=cslib.csinfo&siteid=csius&nodeid1=17218131&treeLang=de&groupid=4000002&e xtranet=standard&viewreg=WW&objaction=csopen). 9.7.1 Torques Table 9-2 Tightening torque for screws 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 M12 50.0 443 115.0 1020 88.0 779 M16 115.0 1020 270.0 2390 215.0 1900 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. 1 Hard materials S2 are materials with friction-enhancing washer components, e.g. a contact washer. 2 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 201 Maintenance 9.7 Repairs 3 Hard S1 materials include steel, for example. Table 9-3 Tightening torques for screw terminals for copper cables without cable lug 1) Screw type Set screws and headless screws nm in - lb Head screws with slit nm in - lb - Head screws with hexagon profile 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, VED 609-1 Note Replacing the current transformer The current transformer may only be replaced by technicians trained by Siemens. Note Defective door interlock system Contact Customer Support if the door interlock system becomes defective. See also Service & Support (Page 229) 202 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Maintenance 9.7 Repairs 9.7.2 Attaching the changing device to the stacker WARNING Improper operation of the changing device If the component to be replaced phase falls from the roller conveyors of the changing device, death or serious bodily injury can result. For your personal safety, please always follow these instructions: Secure the component to be replaced. Handle and install the changing device according to the regulations. Set up the drive so that it is level and horizontal. Secure the lifting trolley using the brake. Never position yourself under the component to be replaced when rolling it in and out. Required tools Standard RHM 23 stacker, MLFB 6SC8476-1EA00-0AA0 Changing device, MLFB 6SL3986-6YX00-0AA0 Procedure 1. Place the changing device on wooden beams so that the stacker can be positioned under it. Bracket to secure the metal plate Figure 9-9 stop brackets Attaching the changing device to the forklift truck 2. Position the stacker under the changing device, so that the base frame is resting on the forks. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 203 Maintenance 9.7 Repairs 3. Assemble the bracket to secure the base frame in place. Figure 9-10 Attaching the changing device to the forklift truck 4. Insert the outer stop brackets at the points provided to prevent the component to be replaced from rolling away. 9.7.3 Replacing the phase module In the power unit, the power semiconductor modules (IGCT), gating boards and balancing resistors are arranged on phase modules. A power unit comprises three phase modules. The IGCT phase module is a replaceable unit. Its weight is 260 kg. The entire IGCT phase module must be withdrawn from the drive so that it can be repaired. Required tools A suitable, flat cooling water catchment tray with a capacity of at least seven liters for draining the drive Open-ended spanner (16 mm, 18 mm, 22 mm) Socket spanner set Prerequisite Prepare the changing device as described in Section "Attaching the changing device to the stacker (Page 203)". 204 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Maintenance 9.7 Repairs Preparation 1. Remove the electrical connections from the lifting solenoids . 2. Loosen the screws connecting the central brace with the frame of the cabinet, and remove the central brace. Figure 9-11 Lifting solenoid Removing the cooling water 1. Place the catchment tray under the pipe union. 2. Close the inlet non-return valve and the outlet non-return valve . Unscrew the water supply and outlet pipes . Figure 9-12 Water connection 3. Capture the cooling water (approximately 5 liters) using the catchment tank. Remove all water from the phase module. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 205 Maintenance 9.7 Repairs Removing cables and screwed connections 1. Pull out the fiber-optic conductors. 2. Remove the power supply cables on the transformers. Figure 9-13 Fiber-optic conductors and power supply cable 3. Release the screwed connections between the phase module and the busbar package on the rear of the IGCT phase module. 4. Remove the screwed connections for the phase connections on the interfaces with the IGCT phase module and the drive cabinet on the rear of the drive. Figure 9-14 Busbar package 5. To remove the upper phase module, unscrew the motor current acquisition module. Release the side screws . Figure 9-15 206 Motor current acquisition module SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Maintenance 9.7 Repairs Mounting the busbars 1. Prior to mounting, insert the supplied long screws through the respective holes of the busbar. 2. Screw the busbars tightly in the cabinet. Note the installation position of the busbars at the upper phase module. Unlike the installation of the busbars at the center and lower phase module, the long end of the busbar must point forwards for the upper phase module. Note To allow the upper busbars to be installed, you must remove the fan. Long side Short side Figure 9-16 Busbar 3. Fasten the phase module to the busbar. The following figure shows the installed busbars in the dismantled state of the phase module. Phase module top Phase module center and bottom Figure 9-17 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Installing the busbars 207 Maintenance 9.7 Repairs Lifting out the module 1. Loosen the screwed connections between the phase module frame and the insulators. 2. Raise the IGCT phase module a few millimeters. To do so, insert a washer on the screw in each case. To do so, insert the screws from above through the lugs on the front and rear of the IGCT phase module. Tighten the nuts slightly. Figure 9-18 Insulators of the phase module and lifting lugs 3. Slide the two roller tracks under the raised frame of the IGCT phase module. Use the screws which were previously used for the screwed connection of frame and insulators to fix the roller tracks in place. Figure 9-19 Changing device: roller tracks 4. Position the stacker with the pre-mounted changing device in such a way that the roller tracks under the IGCT phase module and the roller tracks on the stacker can be screwed together. 208 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Maintenance 9.7 Repairs 5. Allow the IGCT phase module to slide down the roller tracks by unscrewing the connections on the lugs. Figure 9-20 Changing device: joining the roller tracks 6. Pull the IGCT phase module onto the stacker. Secure the module with the two stop brackets . Figure 9-21 Changing device: stop brackets 7. Remove the screwed connections for the roller tracks, which are now joined together. 8. Place the defective phase module down in a suitable place (e.g. on the wooden beams you used for placing the changing device on the stacker). SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 209 Maintenance 9.7 Repairs 9. Fasten the four eyebolts on the phase module. Position the stacker so that you can hang the eyelets on the fork. Figure 9-22 Phase module (placed down) 10.Lift up the phase module and put it to one side. 11.Now lift the new phase module in the same manner from the transport packaging. Place the phase module on the changing device. Installing the module 1. Install the intact module in the reverse order of the previously described steps. 2. When tightening the screws, make sure that you use the appropriate torque (Page 201) permissible for each screw type. 3. Tighten the joints between the water pipes by hand. Performing final checks 1. Open the valves. 2. Make sure that the connections are tight. 3. Make sure that the flow is ensured once the re-cooling unit has been switched in. 210 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Maintenance 9.7 Repairs Note It is not necessary to vent the phase module. Check the water level in the expansion vessel of the re-cooling unit. If necessary, add water. You can find more detailed information on this in the chapter "Description of components" in the "Re-cooling unit" section. 9.7.4 Replacing the diode module The diode module is a replaceable unit. Its weight is 220 kg. The entire diode module must be withdrawn from the drive so that it can be repaired. Required tools Cooling water catchment tank for emptying the drive Open-ended spanner (22 mm) Prerequisite Prepare the changing device as described in Section "Attaching the changing device to the stacker (Page 203)". SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 211 Maintenance 9.7 Repairs Removing the module 1. Loosen the screws connecting the central brace with the frame of the cabinet, and remove the central brace. Figure 9-23 Diode module: water connection 2. Close the inlet non-return valve and the outlet non-return valve . Unscrew the water supply and outlet pipes . Capture the cooling water using the catchment tray. Remove all water from the diode module. Figure 9-24 212 Diode module: phase connections SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Maintenance 9.7 Repairs 3. Remove the screwed connections for the phase connections on the interfaces with the diode module and with the drive cabinet on the rear of the drive. Figure 9-25 Diode module: insulators 4. Loosen the screwed connections between the diode module frame and the insulators. Figure 9-26 Diode module: lugs 5. Lift the diode module by a few millimeters. To do so, insert the screws (size M16x150) through the lugs on the diode module frame from above. Figure 9-27 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Changing device: roller tracks 213 Maintenance 9.7 Repairs 6. Slide the two roller tracks under the raised frame of the diode module. Use the screws which were previously used for the screwed connection of frame and insulators to fix the roller tracks in place. Figure 9-28 Changing device: joining the roller tracks 7. Position the stacker with the pre-mounted changing device in such a way that the roller tracks under the diode module and the roller tracks on the stacker can be screwed together. 8. Allow the diode module to slide down the roller tracks by unscrewing the connections on the lugs. Figure 9-29 Changing device: stop brackets 9. Pull the diode module onto the stacker. Secure the diode module with two additional stop brackets . 10.Remove the screwed connections for the roller tracks, which are now joined together. Installing the module 1. Install the intact module in the reverse order of the previously described steps. 2. When tightening the screws, make sure that you use the appropriate torque (Page 201) permissible for each screw type. 3. Tighten the joints between the water pipes by hand. 214 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Maintenance 9.7 Repairs 9.7.5 Replacing the operator panel To replace the operator panel, proceed as follows: 1. Switch off the main circuit-breaker. 2. Open the cabinet. Power supply Communication cable Retaining lug Figure 9-30 Replacing the operator panel 3. Disconnect the power supply and communication cable at the operator panel. 4. Press the retaining lugs and withdraw the operator panel to the front. 5. Snap on a new operator panel. 6. Attach the connectors for the power supply and communications cable. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 215 Maintenance 9.7 Repairs 9.7.6 Replacing the CompactFlash card To replace the CompactFlash card, proceed as follows: 1. Ensure that the Control Unit is de-energized. NOTICE Destruction of the CompactFlash card The CompactFlash card must only be inserted or removed when the power is off. Otherwise there is a risk of data loss or damage to the card, which would prevent commissioning of the drive. Only remove or insert the CompactFlash card when the power is switched off. 2. Withdraw the CompactFlash card from the Control Unit. Back up the data saved on it. 3. Copy the stored data of the previous CompactFlash card to the new original Siemens card. 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. 4. Insert the new Siemens CompactFlash card. 9.7.7 Replacing the precharging transformer WARNING Incorrect replacement of the precharging transformer Replacing the precharging transformer incorrectly can result in death, serious injury, or material damage. Follow "the five safety rules (Page 19)". Before replacing the precharging transformer, switch off the safety transformer for the 400 V infeed. Lift the transformer carefully because it is heavy (approx. 45 kg). Removing the precharging transformer 1. Detach the 400 V connecting cables . 2. Remove the high-voltage cables . 3. Remove the fixing screws on the base brackets . 4. Remove the transformer. 216 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Maintenance 9.7 Repairs Figure 9-31 Replacing the precharging transformer Installing the precharging transformer 1. Remove the paint from at least one screw position on the base brackets. This is where the transformer will be grounded. 2. Install the new transformer in the reverse order to when you removed it. 3. Check that the precharger is working correctly. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 217 Maintenance 9.7 Repairs 9.7.8 Replacing the precharging rectifier Removing modules Fastening nut Figure 9-32 Replacing the precharging rectifier 1. Remove all connecting leads. If necessary, remove the cable ties. Note Noting the core markings The cables are equipped with Faston connectors. Make a note of the core markings. When installing the new module, note the core markings for the cables. 2. Remove the five plastic nuts of the module. Installing a module Install the new module in the reverse order to when you removed it. 218 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Maintenance 9.7 Repairs 9.7.9 Replacing the AVT combination module Removing the AVT combination module 1. Follow "the five safety rules (Page 19)". 2. Detach the cable connections . 3. Remove the four fixing screws of the AVT combination module. Figure 9-33 Example of an AVT combination module Installing the AVT combination module 1. Use the screws to secure the AVT combination module. 2. Reconnect the control lines . Do not bend the fiber-optic conductors. 9.7.10 Replacing fuses To replace the -F11, -F12 or -F21 fuses, proceed as follows: 1. Disconnect the auxiliary power supply. 2. Remove the defective fuse. 3. Rectify the cause of the fault. 4. Fit the replacement fuse and close the fuse holder. The order numbers for replacing fuses that have blown can be found in the spare parts list. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 219 Maintenance 9.7 Repairs 9.7.11 Replace the sponge for the leak detector Principle of operation If the sponge is dry (hard), the switch is closed. If there is water in the drive, the sponge becomes soft and the switch opens. Sponge hard, switch is closed Sponge soft, switch is opened Figure 9-34 220 Sponge SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Maintenance 9.7 Repairs Replacing the sponge Retaining screws Sponge Figure 9-35 Replacing the sponge 1. Remove the retaining screws . 2. Take out the sponge . 3. Insert a new sponge and then push it up to the stop of the screw. 4. Reattach the leakage water detection. Note Insert the sponge Make sure that the leakage water measurement is on the bottom pan. The distance between sponge and bottom pan is then approx. 1 mm. 9.7.12 Replacing the Power Stack Adapter Required tools Torx screwdriver Tx30 2.5 mm slotted screwdriver SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 221 Maintenance 9.7 Repairs Removing the Power Stack Adapter 1. Disconnect all fiber-optic cables at the following terminals: - X21-X66 - X70-X79 - X81 Ensure that the disconnection is made only directly on the connector and not on the fiberoptic cable. 2. Disconnect all DRIVE-CLiQ cables directly at the connector on terminals X200-X202. 3. Use a slotted screwdriver to remove the green connectors for the control cables at the following terminals: - X210 - X221/222 - X231/232 - X241/242 4. Disconnect the connectors for the control cables from the terminal strip. 5. Remove the ground connection on the Power Stack Adapter chassis. 6. Use a Torx screwdriver to loosen the four fastening screws of the Power Stack Adapter. Do not remove the screws. 7. Push the Power Stack Adapter upwards. 8. Remove the Power Stack Adapter. Sending in the Power Stack Adapter You can send in the defective Power Stack Adapter for a special examination. Further information is contained in the note "Special examination of defective components (Page 200)". Observe the following when you send in a component: 1. Close the fiber-optic cable connectors with blanking plugs. 2. Send the defective Power Stack Adapter only in the approved packaging. 222 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Maintenance 9.7 Repairs Installing the Power Stack Adapter 1. Execute the steps described in the section "Removing the Power Stack Adapter" in the reverse order. 2. Tighten the fastening screws with a torque of 10 Nm. 3. Ensure the correct connection of the fiber-optic cables. NOTICE Faulty connection of fiber-optic cables The faulty connection of the fiber-optic cables on the Power Stack Adapter can damage the power semi-conductors. Observe the connector assignment marked on the fiber-optic cables. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 223 Maintenance 9.7 Repairs 224 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Spare parts 10 NOTICE Non-approved spare parts Using non-approved spare parts can affect the function of the equipment and damage it. Thirdparty spare parts and unapproved spare parts may not meet the requirements. Therefore, only use spare parts that have been approved by the manufacturer. To request spare parts, please contact the Siemens sales office responsible for your region. You can find an overview of the Siemens contact partners in your region here (www.siemens.com/services/partner). Note Always indicate the part number and - if known - the order number (MLFB) 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 supplied with the drive indicates the part number and, where appropriate, the order number corresponding to the item code. For inquiries by e-mail, if possible send a photograph of the product, spare part, rating plate. Use Spares on Web (https://b2b-extern.automation.siemens.com/ spares_on_web(bD1kZSZjPTA4MCZkPW1pbg==)/default.htm) to obtain information about spare parts for your drive. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 225 Spare parts 226 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 11 Disposal Observe Chapter, "Safety instructions" when carrying out any work at the converter. 11.1 Disposing of packaging material The packing is designed in such a way as to pose the minimum risk to the environment. Some of the packaging can be recycled. The disposal of packaging is controlled by country-specific laws. If in doubt, ask your local disposal specialists or contact the local authorities. The packing material consists of the following components: Wooden frames Wooden pallets Polyethylene foil Plywood Plastic Silica gel 11.2 Removing device components and old devices If you correctly dispose of the materials, none of the materials pollutes the environment. When disposing or reusing, comply with the local laws and regulations. WARNING Improper disassembly In the event of an improper procedure during disassembly, material can slip, tilt, and fall down. This can result in death, serious injury or material damage. Only specialist personnel may disassemble and dispose of device components and old devices using appropriate protective clothing. Switch off the drive before you start to dismantle it. Ground the device With old devices, also follow the instructions in the section "Transport." For the following components, pay special attention when disposing or reusing: Batteries Capacitors SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 227 Disposal 11.2 Removing device components and old devices PCBs Electronic components 228 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Service & Support A Technical questions or additional information If you have any technical questions or you require additional information, please contact the Technical Support. Please have the following data ready: Type Serial number You can find this data on the rating plate. Contact person If you wish to request on-site service or order spare parts, please contact your local office. This office will contact the responsible service center on your behalf. You can find your contact person in the relevant contact database: www.siemens.com/your contact See also Technical Support (https://support.industry.siemens.com/cs/ww/en/sc/2090) www.siemens.com/yourcontact (www.siemens.com/yourcontact) Siemens Support for on the move You can obtain optimum support anywhere you go using the "Siemens Industry Online Support" app. The app is available for Apple iOS, Android and Windows Phone. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 229 Service & Support 230 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Technical data and drawings B.1 Technical specifications B.1.1 Notes about technical specifications B An overview of general and specific technical data of the device is provided in the following. Further, you will find directives relating to the conditions that you must comply with when using the described device. B.1.2 Table B-1 Standards and regulations Standards and conformity Standards Standards DIN EN 61800-3/VDE 0160 T103 (IEC 61800-3) DIN EN 61800-4 / VDE 0160 T104 (IEC6 1800-4), however, only when referenced in the standards DIN EN 61800-3 or DIN EN 61800-5-1 DIN EN 61800-5-1/VDE 0160 T105 (IEC 61800-5-1) EU directives Up to April 19, 2016 2006/95/EC + amendments (Low Voltage Directive) 2004/108/EC + amendments (Electromagnetic Compatibility) from April 20, 2016 2014/35/EU + amendments (Low Voltage Directive) 2014/30/EU + amendments (Electromagnetic Compatibility) Certificate of compliance with order For the EMC Directive (2004/108/EC + amendments or 2014/30/EU + amendments) (Product cannot be operated independently; limited distribution channel) Interference omission This drive unit is part of a PDS, Category C4 according to DIN EN 61800-3/ VDE 0160 T103 (IEC 61800-3). The drive unit has not been designed to be connected to the public line supply. The equipment can cause electromagnetic interference when it is connected to the public grid. The essential requirements placed on EMC protection for the drive system should be secured using an EMC plan at the customer site. Insulation According to DIN EN 50178/VDE 0160 (IEC 62103), IEC 61800-5-1: Pollution degree 2 (without conductive pollution), non-condensing Degree of protection In accordance with DIN VDE 0470 T1, EN 60 529, IEC 60 529 Protection class Class 1 according to DIN EN 61800-5-1/VDE 0160 T105 (IEC 61800-5-1) Touch protection DIN EN 50274/VDE 0660 T514 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 231 Technical data and drawings B.1 Technical specifications B.1.3 Series connection variant of Basic Line Modules (option N15) Figure B-1 B.1.4 24-pulse supply with series connection of two Basic Line Modules Connection variant: Performance enhancement through parallel operation of three drive units Figure B-2 1) 232 Performance enhancement with parallel operation of three complete drive units 1); 36-pulse supply possible Requires a motor with separate winding systems. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Technical data and drawings B.1 Technical specifications B.1.5 Table B-2 General technical specifications of the drive General technical specifications Technical specifications Power components Diodes/IGCT Line-side converter Standard: 12-pulse diode rectifier (Basic Line Module) Option: 24-pulse diode rectifier (Basic Line Module) Motor-side converter Inverter (Motor Module) Closed-loop control TRANSVEKTOR closed-loop control Drive quadrants 2 (driving in 2 directions of rotation) Electrical isolation of power unit/ open-loop control and closed-loop control Fiber-optic cables and isolating transformer Auxiliary power supply 1-phase 230 VAC 10%, 50/60 Hz 3% and one of the following voltages: 3-phase 400 VAC 10%, 50/60 Hz 3% or a different auxiliary voltage (option Y75) Installation altitude 1000 m above sea level: 100% load-carrying capacity > 1000 m to 400 m above sea level: current derating required > 2000 m to 4000 m above sea level: additional voltage derating required Current and voltage derating 3HUPLVVLEOHUDWHGFXUUHQW 3HUPLVVLEOHUDWHGLQSXWYROWDJHLQDFFRUGDQFHZLWK 9'(,(& P $VVHPEO\KHLJKWLQPDERYHVHDOHYHO P $VVHPEO\KHLJKWLQPDERYHVHDOHYHO Insulation Degree of contamination 2 without conductive pollution according to EN 50178 / VDE 0160 (IEC 62103), condensation not permissible Degree of protection according to EN 60529 / VDE 0470 T1 (IEC 60529): Standard: IP43 Option: - Safety class Class 1 according to EN 61140 / VDE 0140 T1 (IEC 61140) Touch protection BGV A3 Radio interference level According to EN 61800 3: no radio interference suppression Paint/color Indoor requirements / light gray RAL 7035 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 233 Technical data and drawings B.1 Technical specifications Table B-3 Cooling Cooling Type of cooling Water cooling (integrated water-to-water re-cooling unit), internal circuit, deionized water Permissible coolant temperature (raw water) Inlet: +5 C to +35 C Sequence: max. +40 C Climatic environmental conditions Table B-4 Climatic environmental conditions 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% (Only low condensation is permitted. The drive must be completely dry before com missioning.) 5% to 75% 5% to 85% (Condensation is not permit ted) Other climatic conditions ac cording to class 1K3 according to DIN EN 6072131 (IEC 6072131) 2K2 according to DIN EN 6072132 (IEC 6072132) 3K3 according to DIN EN 6072133 (IEC 6072133) Pollution degree 2 without conducting contam ination according to DIN EN 61800-5-1 / VDE 0160 T105 (IEC 61800-5-1) 2 without conducting contam ination according to DIN EN 61800-5-1 / VDE 0160 T105 (IEC 61800-5-1) 2 without conducting contam ination according to DIN EN 61800-5-1 / VDE 0160 T105 (IEC 61800-5-1) Mechanical ambient conditions Table B-5 Mechanical ambient conditions Storage with suitable packag Transport with suitable pack Operation ing aging Class 234 1M2 according to DIN EN 6072131 (IEC 6072131) 2M2 according to DIN EN 6072132 (IEC 6072132) 3M1 according to DIN EN 6072133 (IEC 6072133) SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Technical data and drawings B.1 Technical specifications Other ambient conditions Table B-6 Other ambient conditions Storage with suitable packag Transport with suitable pack Operation ing aging Biological ambient conditions 1B1 according to DIN EN according to class 6072131 (IEC 6072131) 2B1 according to DIN EN 6072132 (IEC 6072132) 3B1 according to DIN EN 6072133 (IEC 6072133) (without harmful flora) Chemically active substan ces according to class 1C1 according to DIN EN 6072131 (IEC 6072131) 2C1 according to DIN EN 6072132 (IEC 6072132) 3C1 according to DIN EN 6072133 (IEC 6072133) Mechanically active substan 1S1 according to DIN EN ces according to class 6072131 (IEC 6072131) 2S1 according to DIN EN 6072132 (IEC 6072132) 3S1 according to DIN EN 6072133 (IEC 6072133) B.1.6 Table B-7 Technical specifications of the common power supply Technical specifications of the common power supply Rated voltage UErated / rated input frequency fErated: 1-phase 115 VAC / 60 Hz 1-phase 230 VAC / 50 Hz / 60 Hz 1-phase 240 VAC / 50 Hz / 60 Hz Peak value of the rated output voltage UArated: 55 V 3% Rate of rise of voltage (dva/dt)max: 2 kV/s Rated output frequency fArated: 100 kHz 5% Natural convection, TEnv = 55 C, PA1Rated: 87.5 W for UERATED = 230 V Rated total power output with natural convection, TEnv = 55 C, PA1Rated: 350 W for UERATED = 230 V 300 W for UERATED = 115 V 75 W for UERATED = 115 V Possible load duty cycle Transient, 60 s - 1.2 x PARated Recovery time 30 minutes Mean value of output current per half-period per output, IARated: 1.25 A Peak value of output current during rated operation per output, IAmax: Approx. 6.5 A Switch-off overcurrent limit value per output, IAoff: 10 A Efficiency under rated conditions > 80% B.1.7 Table B-8 Technical specifications of the diagnostics module DM10 Technical specifications of the AD586LR reference element Version AD586LR Output voltage 5 V 2.5 mV Deviation of the output voltage for 0 C up to 70 C 5 ppm/C SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 235 Technical data and drawings B.2 Terminal assignments Version AD586LR Deviation for T = 25 C 100 V/mA Max. change of the output voltage (T)max = 70 C 1.75 mV B.2 Terminal assignments B.2.1 Control pulpit interface (Terminal Modules TM31 and TM15) Table B-9 Terminal assignment of customer interface TM15 Terminal module Connec Terminal tor .HC-A31 -X520 -X521 -X522 Table B-10 3 DI p4022.1 p840 ON/OFF 1 4 DI p4022.2 p844 OFF 2 5 DI p4022.3 p848 OFF 3 6 DI p4022.4 p2103 Acknowledge faults 7 DI p4022.5 8 DI p4022.6 p852 Enable operation 9 DI p4022.7 p1035 MOP raise 2 DI p4022.8 p1036 MOP lower 3 DI p4022.9 p1020 Fixed speed setpoint bit 0 4 DI p4022.10 p1021 Fixed speed setpoint bit 1 5 DI p4022.11 6 DI p4022.12 p1113 Direction reversal 7 DO p4022.13 r899.0 Message: Ready for switching on 8 DO p4022.14 r899.1 Message: Ready for operation 9 DO p4022.15 r899.2 Message: Operation enabled 2 DO p4022.16 r899.3 Message: Fault active 3 DO p4022.17 r899.7 Message: Alarm active 4 DO p4022.18 r807 Local operation 5 DO p4022.19 r2197.3 Drive rotating clockwise Local control (AOP30/PC) Profibus switchover Terminal assignment of customer interface TM31 Terminal module Connec Terminal tor .HC-A31 -X521 236 Internal control Internal control 1,2 AI p4052.0 p1070 Main speed setpoint 3,4 AI p4052.1 p1075 Supplementary speed setpoint 1,2 AO p4071.0 r0063 Actual speed value 4,5 AO p4071.1 Supplementary actual speed value SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Technical data and drawings B.2 Terminal assignments B.2.2 Terminal assignment of the NAMUR terminal strip (option B00) The NAMUR terminal strip is a standard terminal strip defined for the chemicals/ pharmaceutical industry. It is defined as follows: Table B-11 Terminal assignment of NAMUR terminal strip Terminal No. Designation Preassignment Comments -A1-X2 1 1.0 1.1 M Reference conductor to 24 VDC supply 3 3.0 3.1 P24 24 VDC supply 10 DI ON command drive 11 DI OFF (dynamic) 12 DI Faster MOP raise 13 DI Slower MOP lower 14 DI RESET Acknowledge faults 15 DI Lock 16 DI Counterclockwise 3 terminals Protected internally with fuse (2 A) 3 terminals See .HC -A31 -X520:3. OFF3 "0" signal for CW phase sequence "1" signal for CCW phase sequence direction of rotation changeover 17, 18 Power disconnection External safety circuit Circuit-breaker no OFF command 30, 31 Ready for operation Relay output (NO contact) Operation; motor turning Relay output (NO contact) 32, 33 34 DO (COM) Fault 35 DO (NO) 36 DO (NC) 50, 51 AI 0/4 mA to 20 mA Speed setpoint 60, 61 AO 0/4 mA to 20 mA Main actual speed value 62, 63 AO 0/4 mA to 20 mA Motor current Relay output (two-way contact) Defaulted with motor current - can be repara meterized for other variables. See also NAMUR terminal strip (option B00) (Page 55) SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 237 Technical data and drawings B.2 Terminal assignments B.2.3 Table B-12 Circuit-breaker interface Terminal assignment for circuit-breaker interface .LA -X11 Terminal Internal control 1 DI r0722.0 p6684[0] Feedback: "Ready to start" 2 DI r0722.1 p6686[0] Feedback: "OFF" 3 DI r0722.2 p6685[0] Feedback: "ON" 4 DI r0722.3 p6689[0] Feedback: "External switchoff" Table B-13 Terminal assignment for circuit-breaker interface .LA -X52 with OFF and undervoltage coil Terminal Internal control 1, 2 3; 4 DO p0738 r6660.0 "ON" command 9 DO p0739 r6660.1 "OFF" command 12 DO p0740 r6660.2 "Undervoltage coil OFF" command Table B-14 Terminal assignment for circuit-breaker interface .LA -X52 with two OFF coils and undervoltage coil Terminal Internal control 1, 2 3; 4 DO p0738 r6660.0 "ON" command 9 DO p0739 r6660.1 "OFF" command 12 DO p0740 r6660.2 "Undervoltage coil OFF" command 15 Table B-15 "OFF undervoltage coil 2" command Terminal assignment for circuit-breaker interface .LA -X52 with capacitor release Terminal Internal control 1, 2 3; 4 DO p0738 r6660.0 "ON" command 9 DO p0739 r6660.1 "OFF" command 13, 15 DO 14 - 17 DO 238 Tripping the circuit-breaker via the capacitor re lease Interface with capacitor release SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Technical data and drawings B.2 Terminal assignments B.2.4 Interfaces of the Power Stack Adapter B.2.4.1 Gating of the power semiconductors B.2.4.2 Number Duplex fiber-optic cable Meaning: Technical data X11 to X14 Inverter phase u X31 to X34 Inverter phase v X51 to X54 Inverter phase w X15 / X16 Crowbar X35 / X36 Braking chopper Gating power semiconductors Fiber-optic cable type: 2 mm plastic optical fiber (POF) Max. length of fiber-optic cable: 20 m Selecting Safe Torque Off Interface Terminal Designation Technical data X241 1 +24 V (internal) Relay, coil data: 2 Relay coil 1 (+) Rated voltage: 24 V DC 3 NC contact Operating range: 21.6 to 26.4 V DC 1 M Relay, contact data: 2 Relay coil 2 (-) Single contact, positively driven 3 NC contact Rated current: 8 A X242 Rated voltage / max. switching voltage: 240/400 V AC Max. switching power 12 W (24 V, 500 mA) Note The internal safety relay must be energized in order to operate the inverter (see Chapter "Gating the power semiconductors"). If the option "Safe Torque Off (STO)" is not available, this circuit function is achieved permanently by inserting jumpers between terminals 1 and 2 of the two connectors X241 and X242. If the option "Safe Torque Off (STO)" is used, the safety relay is controlled by the two terminals 2 of connectors X241 and X242. The feedback information from the NC contact terminal 3 at X241 and X242 is evaluated in a higher-level safety control to check the switching state. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 239 Technical data and drawings B.2 Terminal assignments B.2.4.3 Actual value channels Table B-16 B.2.4.4 Power Stack Adapter 2: Actual value channels Single fiber-optic cable Meaning, actual value acquisition Technical specifications X70, X71 DC-link voltages X72, X73 Output currents Fiber-optic cable type: 2 mm plastic optical fiber (POF) X74, X75 Output voltages X76 to X78 N.C. X79 Voltage sensing braking chopper Max. length of fiber-optic cable: 20 m Trip line Table B-17 Power Stack Adapter 2: Trip line Fiber-optic cable Meaning Technical data X81 Trip line for direct data ex change between PSAs Fiber-optic cable type: Two PSAs Duplex fiberoptic cable; 2 mm plastic optical fiber (POF) Max. length of fiber-optic cable: 10 m > two PSAs Single fiberoptic cable) B.2.4.5 DRIVE-CLiQ interface Table B-18 DRIVE-CLiQ interface Pin Signal name Technical data 1 TXP Transmit data + 2 TXN Transmit data - 3 RXP Receive data + 4 Reserved, do not use 5 Reserved, do not use 6 RXN 7 Reserved, do not use 8 Reserved, do not use A + (24 V) Power supply B M (0 V) Electronics ground Receive data - Blanking plate for DRIVE-CLiQ interface: Molex, order number: 85999-3255. The maximum DRIVE-CLiQ cable length is 50 m. 240 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Technical data and drawings B.2 Terminal assignments B.2.4.6 Analog and digital outputs Table B-19 Terminal Power Stack Adapter 2: Analog and digital outputs Designation X231 1 Technical specifications X232 M Max. output voltage: 2 DO 3 DO 7 Supply voltage at X210.3 minus approximately 2 V 3 DO 2 DO 6 Max. load current per output: 4 M 300 mA, continuously short-circuit-proof 5 M Output delay: 6 DO 1 7 DO 0 8 DO 5 For "0" to "1": Typ. 100 s at 0.3 A resistive load DO 4 For "1" to "0": Typ. 10 s at 0.3 A resistive load M 9 AO 3- AO 7- 10 AO 3+ AO 7+ 11 AO 2+ AO 6+ 12 AO 2- AO 6- 13 AO 1- AO 5- 14 AO 1+ AO 5+ 15 AO 0+ AO 4+ 16 AO 0- AO 4- Voltage range: 0 V to 10 V, short-circuit proof Max. load current per output: 3 mA Resolution: 12 bits Max. connectable cross-section 1.5 mm; type: Screw terminal B.2.4.7 Switch for the analog inputs Table B-20 Power Stack Adapter 2: Switch for the analog inputs Switch Function Technical specifications S5.0 Switchover, analog input AI0: S5.1 Switchover, analog input AI1: Current range 0 mA to 20 mA, can be additionally reduced to 4 mA to 20 mA via software (wire-break monitoring); Voltage (V)/Current (I) Voltage (V)/Current (I) SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Voltage range 0 V ... 10 V 241 Technical data and drawings B.2 Terminal assignments B.2.4.8 Analog and digital inputs and temperature sensor connections Table B-21 Power Stack Adapter 2: Analog and digital inputs and temperature sensor connections Terminal Designation X221 1 DI 3 Technical specifications X222 DI 7 2 +24 V (auxiliary voltage) 3 +24 V (auxiliary voltage) 4 DI 2 DI 6 5 DI 1 DI 5 6 +24 V (auxiliary voltage) 7 +24 V (auxiliary voltage) 8 DI 0 DI 4 9 MEXT1 (poten tial-free refer ence for MEXT2 (poten tial-free refer ence for DI 0, DI 1, DI 4, DI 5, DI 2 and DI 3) DI 6 and DI 7) 10 M Auxiliary voltage: Voltage: 24 VDC Max. total load current of + 24 V auxiliary voltage of terminals X221 and X222 combined: See note. Input voltage range: - 3 V to 30 V Typical current consumption: 10 mA at 24 VDC Input delay: For "0" to "1": Max. 50 s For "1" to "0": Max. 100 s Electrical isolation: Reference potential is terminal MEXT1 or MEXT2 Level (including ripple): High signal level: 15 V to 30 V Low signal level: - 3 V to 5 V 11 AI 0 AI 1 12 AI 0- AI 1- The analog input can be switched between current input and voltage input using the S5.0 and S5.1 switches. Voltage: 0 V to 10 V; Ri > 100 kOhm; resolution 12 bits Current: 0 mA to 20 mA; Ri = 250 Ohm; resolution 11 bits 13 TEMP 0- TEMP 1- 14 TEMP 0 TEMP 1 Two-wire PT100 temperature sensor Max. connectable cross-section: 1.5 mm, type: Screw terminal Note Maximum load current from the 24 VDC auxiliary voltage and the digital outputs The total load current through terminals 2, 3, 6, 7 at X221 and X222 of the 24 VDC auxiliary voltage together with the digital outputs is protected by an internal 4 A fuse. A continuous current of 3 A in total through this fuse must not be exceeded. In your application, dimension the total load currents from the eight digital outputs and the terminals of the 24 VDC auxiliary voltage accordingly. 242 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Technical data and drawings B.2 Terminal assignments Note Open input An open input is interpreted as "low". To enable the digital inputs to function, connect terminals MEXT1 and MEXT2. This is done in one of the following ways: The incorporated ground reference of the digital inputs A jumper to terminal M In this case, the isolation for these digital inputs is removed. Note Diagnosis when the 24 VDC auxiliary voltage fuse ruptures The 24 VDC auxiliary voltage is protected internally by a 4 A fuse. A ruptured fuse is indicated by loss of the auxiliary power and/or by a diagnostic message. All digital outputs are also affected by a ruptured fuse. You will not be able to replace this fuse. Replace the component and send it for repair. B.2.4.9 Electronics power supply Table B-22 Power Stack Adapter 2: Electronics power supply Terminal Designation Technical specifications 1 Electronics ground M Voltage: 24 VDC (18 V to 31.2 V, -25% to +30%) 2 N.C. 3 Electronic power supply P24 Power consumption (without DRIVE-CLiQ or digital out puts): 1 A max. Max. connectable cross-section: 2.5 mm Type: Screw terminal SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 243 Technical data and drawings B.2 Terminal assignments 244 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Checklists and forms C.1 C Mechanical installation: Checklist Logbook Use the following checklist to guide you through the mechanical installation procedure for the cabinet unit. Read the safety information at the start of these operating instructions before you start working on the device. Note If the option in question is part of the delivery, check this accordingly in the right-hand column. Check the boxes once you have finished the installation procedure to confirm that the activities are complete. Item 1 Activity Available / Completed The environmental conditions must be permissible. For more information, see the "Tech nical specifications" section. If the drive and re-cooling unit are installed separately, the bottom level (switch-off level) of the expansion tank must be located above the highest water level in the drive. 2 Connect the raw water circuit and the de-ionized water circuit. Remove any contamination from the piping that may have occurred during shipment or storage. 3 Fill and vent the de-ionized water circuit according to the specifications. Ensure that no air is trapped in the piping system. 4 Install the separately supplied components. Make the required mechanical and electrical connections as well as the connection to the de-ionized water circuit. 5 The clearance around an open door (escape route) specified in the applicable accident prevention guidelines must be observed. 6 For option M13/M78: Select the required metric gland or PG gland appropriate for the cable cross-section. Proivde the appropriate holes in the cover plates. When the cable is fed in from above, ensure that enough room is available if the cable has to be bent because of the cable feeder and cross-sections. To prevent lateral forces on the entries, insert the cable verti cally. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 245 Checklists and forms C.2 Checklist for electrical installation C.2 Checklist for electrical installation Logbook Use the checklist below to guide you through the electrical installation procedure for the drive. Read the safety information at the start of these operating instructions before you start working on the device. Note If the option in question is part of the delivery, check this accordingly in the right-hand column. Check the boxes once you have finished the installation procedure to confirm that the activities are complete. Item Activity Available 1 If the drive is shipped in more than one transportation unit due to its dimensions, you must also establish the electrical connections between the cabinet units as well as the mechan ical connections. In addition to the power busbars, establish the electrical connection for the signal and monitoring electronics. 2 Dimension and install the line and motor-side power cables in accordance with the ambient and wiring conditions. Make sure that the maximum cable lengths between the drive and motor are not exceeded. /completed The motor ground must be routed back directly to the cabinet unit. The cables must be properly connected with a torque of 50 Nm to the drive terminals. The cables for the motor and low-voltage switchgear must also be connected with the required torques. 3 The medium-voltage switchgear is a central component of the drive protection concept. For this reason, medium-voltage circuit-breaker control must be integrated in the drive controller. 4 If the medium-voltage switchgear does not have an undervoltage coil or a UPS-supported auxiliary-voltage supply, provide the following alternative: The medium-voltage circuit-breaker must be equipped with an undervoltage coil. Integrated circuit-breaker (option N13) on the secondary side of the transformer Capacitor-release units (option N20 or N21) for the circuit-breaker. 5 Set the overcurrent protection for the medium-voltage circuit-breaker so that it protects the system. 6 To relieve strain on the cables, they must be clamped on the cable propping bar (C-bar). 7 When EMC-shielded cables are used, screwed glands that connect the shield to ground with the greatest possible surface area must be provided on the motor terminal box. 8 Apply the cable shields properly. The cabinet must be properly grounded at the points provided. 9 246 An auxiliary supply (3-phase 380 VAC) must be provided for the auxiliary equipment (e.g. cabinet fan / DC-link precharging). Refer to the "Technical specifications" for the drives for details of current consumption. Protect the low-voltage feeder appropriately at the plant. With respect to the phase sequence, make sure that fans rotate in the right direction. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Checklists and forms C.2 Checklist for electrical installation Item Activity 10 If a voltage other than the auxiliary supply (3-phase 380 - 415 VAC) is used, a suitable matching transformer is required (option Y75). Available /completed Ensure that the chosen taps are appropriate for the voltage present. With respect to the phase sequence, make sure that fans rotate in the right direction. 11 The open-loop and closed-loop control systems are supplied with voltage (230 VAC 50/60 Hz) via terminals. Refer to the "Technical specifications" for the drives for details of current consumption. If communication with the open-loop and closed-loop control system is to be maintained even if the main voltage fails or the drive is to be switched on again auto matically if the power fails, this voltage must originate from a secure network. Alternatively, choose option L53 (UPS-supported power supply for the closed-loop control system). 12 Connection for external auxili ary equipment (option L19) 13 Cabinet anticondensation heating (option L55) To supply auxiliary equipment (e.g. separately-driven motor fan), the drive must be properly connected to terminals X155:1 (L1) to X155:3 (L3). The supply voltage of the auxiliary equipment must match the input voltage of the drive. The load current must not exceed 10 A and must be set in accordance with the connected consumer. Set value: _________________ If the drive is equipped with option L55 (cabinet anti-condensation heat ing), provide the required auxiliary voltage (V) via the terminals. Protect the auxiliary supply with fuses on the low-voltage distribution board side. This voltage is not integrated in the EMERGENCY STOP sequence of the drive and is, therefore, present even when the EMERGENCY STOP button has been actuated. These cabinet-internal cables can be easily identified by their orange insulation. Provide for the service power sockets in the control cabinet as well as for the optional cabinet lighting (option L50) on the auxiliary voltage supply 230 V). Protect the auxiliary voltage supply with 10 A fuses on the plant. This voltage is not integrated in the EMERGENCY STOP sequence of the drive and is, therefore, present even when the EMERGENCY STOP button has been actuated. These cabinet-internal cables can be easily identified by their orange insulation. To supply auxiliary equipment (e.g. separately-driven fan for motor), the drive must be properly connected to terminals (L1) to (L3). The supply voltage of the auxiliary equipment must match the input voltage. The voltage is supplied at terminals X ... Depending on which option (option N30 to N33) is chosen, different circuit-breakers are available with the assigned motor circuit-breaker. When connecting the power supply, take into account the direction of rotation of the drive. Set the motor circuit-breaker so that it protects the drive. Protect the auxiliary supply for the auxiliary equipment (e.g. separately-driven motor fan) with fuses on the system side. The circuit-breaker is activated by means of the "Aux iliary equipment ON" command from the drive controller. 13 Drive operation by higher-level controller / control room. Connect the control lines as specified in the interface assignment. Connect the shield. Route the digital and analog signals with separate cables to minimize interference. Ensure that the required distance from the power cables is maintained. Set selector switches S5.0 / S5.1 appropriately when the analog inputs on the customer terminal strip are used as current or voltage inputs. SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 247 Checklists and forms C.2 Checklist for electrical installation Item Activity Available /completed To supply the anti-condensation heating for the motor or the working machine, the drive must be properly connected to terminals (L1) to (L3). The supply voltage of the anti-condensation heating must match the input voltage. The voltage is supplied at terminals X ... Depending on which option (option N35 to N38) is chosen, different circuit-breakers are available with the assigned motor circuit-breaker. Set the motor circuit-breaker so that it protects the anti-condensation heating. Protect the auxiliary supply for the anti-condensation heating with fuses on the system side. The circuit-breaker is activated by means of the "Auxiliary equipment OFF" command from the drive controller. 17 Option L60 EMERGENCY OFF category 1 (24 VDC) The drive is fitted as standard with a category 0 STOP function and an EMERGENCY OFF button in the control cabinet door. With option L60, EMERGENCY OFF category 1 (decelerate at current limit) is defaulted. If the drive is to be integrated in a central EMERGENCY STOP se quence in the system-side protection concept, floating contacts are available on terminal strip X... Terminal X... allows other EMERGENCY OFF buttons in the system to be looped in. Signal connections 18 Drive operation by higher-level controller / control room. Connect the control cables in accordance with the interface assignment and apply the shield. Route the digital and analog signals with separate cables to minimize interference. Ensure that the required distance from the power cables is maintained. Note that when the analog inputs on the customer terminal strip are used as current or voltage inputs, the isolation amplifiers ( ... ) must be set accordingly. Connecting protection and monitoring devices Depending on the converter transformer version (dry or oil filled), integrate the transformer protection and monitoring devices in the alarm and shutdown train of the drive. A range of digital inputs are available for this purpose on the customer terminal strip. 19 Options L80 to L82 Thermistor mo tor protection unit (alarm/ shutdown) 21 Option L91 PT100 evalua tion unit The PTC thermistor sensors (type A PTC resistors) must be connected to the thermistor motor protection unit F at terminals T1 and T2 for alarm/shutdown purposes. The resistor thermometers must be connected to evaluation unit A140 for the PT100 evaluation. The two-wire or three-wire system can be used here to connect the PT100 sensors. The sensors are divided into two groups. This must be taken into account when the evaluation is performed (factory setting). To check the correct wiring and macro interconnection, first select limits below the ambient temperature and check the messages. After checking the correct wiring and macro interconnection, set the limit values for alarm and shutdown to match the component monitored. 248 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Checklists and forms C.2 Checklist for electrical installation Item Activity 22 Option L93 PT100 evalua tion unit Available /completed The resistor thermometers must be connected to evaluation unit A1.. for the PT100 evaluation. The two-wire or three-wire system can be used here to connect the PT100 sensors. The sensors are divided into two groups. This must be taken into account when the evaluation is performed (factory setting). To check the correct wiring and macro interconnection, first select limits below the ambient temperature and check the messages. After checking the correct wiring and macro interconnection, set the limit values for alarm and shutdown to match the component monitored. Option L94 PT100 evalua tion unit The resistor thermometers must be connected to evaluation unit A1 for the PT100 evaluation. The two-wire or three-wire system can be used here to connect the PT100 sensors. The sensors are divided into two groups. This must be taken into account when the evaluation is per formed (factory setting). To check the correct wiring and macro interconnection, first select limits below the ambient temperature and check the messages. After checking the correct wiring and macro interconnection, set the limit values for alarm and shutdown to match the component monitored. Option L95 PT100 evalua tion unit (for use in hazardous areas) The resistor thermometers must be connected to evaluation unit A1 for the PT100 evaluation. The two-wire or three-wire system can be used here to connect the PT100 sensors. The sensors are divided into two groups. This must be taken into account when the evaluation is per formed (factory setting). To check the correct wiring and macro interconnection, first select limits below the ambient temperature and check the messages. After checking the correct wiring and macro interconnection, set the limit values for alarm and shutdown to match the component monitored. Option L96 PT100 evalua tion unit (for use in hazardous areas) The resistor thermometers must be connected to evaluation unit A1 for the PT100 evaluation. The two-wire or three-wire system can be used here to connect the PT100 sensors. The sensors are divided into two groups. This must be taken into account when the evaluation is per formed (factory setting). To check the correct wiring and macro interconnection, first select limits below the ambient temperature and check the messages. After checking the correct wiring and macro interconnection, set the limit values for alarm and shutdown to match the component monitored. 23 Differential pressure moni toring Check the entry for parameter p0263. The setting must not exceed 3 seconds. 1. In the infeed, select "Test operation cooling" (infeed p6650). 2. Switch on test operation via infeed p6651. 3. In the cooling system, close the main valve for the cooling water feed to the converter. The converter must switch off with the following fault: "F49158 cooling system: Differential pressure has fallen below the fault threshold". 4. Reopen the valve. 5. Acknowledge the fault and switch test operation off again. ( P6651 = 0, P6650 = 0 ) Connecting Sensor Modules SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 249 Checklists and forms C.2 Checklist for electrical installation Item Activity Available Option K50 Sensor Module for detecting the actual motor /completed If a function for detecting the actual speed value is provided to improve speed accuracy, connect the motor rotary pulse encoder to the SMC30 ( A... ). speed Option L32 Voltage Sens ing Module If, for process-related reasons, the drive needs to be restarted after power failures of > 100 ms, connect the synchronization voltage of the line upstream of the medium-voltage circuit-breaker to the VSM 10. To do so, install voltage converters at the medium-voltage level, which supply 3-phase 100 VAC as the synchronization voltage. Connect the voltage converters on the drive side to terminals. Switch-on conditions with water-cooled drives Before switching on the drive for the first time, you must reduce the conductivity of the deionized water circuit to < 1 S. After filling the re-cooling unit, switch it on for several hours before switching on the drive. The conductivity reduction may also be necessary if the drive has been out of service for an extended period (such as maintenance/revision times). Required tools To install the connections, you will require: Spanner or socket spanner (w/f 10) Spanner or socket spanner (w/f 13) Spanner or socket spanner (w/f 16/17) Spanner or socket spanner (w/f 18/19) Hexagon-socket spanner (size 8) Torque spanner, max. 50 Nm Screwdriver, size 2 Screwdriver, Torx T20 Screwdriver, Torx T30 250 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Index A Actual value acquisition, 42, 240 AOP30 operator panel Function, 116 Replacing the backup battery, 197 water sensor, 215 Auxiliary voltage Failure of the auxiliary voltage, 38, 188, 190 Interference suppression, 100 AVT combination module, 42 B Basic Line Module, 33 C Cable cross section Ground connection to the peripherals, 100 Protective ground conductor, 27 Cable cross-section Customer terminal strips, 54 dv/dt filter, 61 Input filter, 62 Power Stack Adapter, 241, 242, 243 Cable length DRIVE-CLiQ interface, 240 dv/dt filter, 61 Input filter, 62 Sine-wave filter, 69 Capacitor DC link capacitor, 21, 37 DC-link capacitor, 37 dv/dt filter capacitor, 60 Filter capacitor, 62 Circuit breaker, 69 At the drive output, 65 Circuit-breaker Crowbar, 170 Safety shutdown, 170 Undervoltage trip, 170 CompactFlash card Loading operator panel firmware, parameter and signal descriptions, 198 Replacing, 216 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Components that can be destroyed by electrostatic discharge (ESD) Guidelines, 24 Crowbar, 32 D Damage during transportation, 71 DC link, 34, 37, 38, 64, 170, 171 Deionized water requirements, 54 Delivery, 71 Door interlock Castell lock, 67 Cover screw, 81 Electromechanical, 38, 67, 189 Manual, 81 Safety locking system, 67, 189 Door lock Electromechanical, 38 DRIVE-CLiQ interface Power Stack Adapter, 40 E Electromagnetic fields, 23 Environmental conditions, 234 F Fiber-optic cable Length, 240 Type, 240 Fiber-optic cables Cleaning, 199 Length, 240 Type, 240 Filter mats, 195 Five safety rules, 19 Fuse Miniature circuit-breaker, 43 Power Stack Adapter, 176, 242 G Grounding ESD shoe grounding strips, 24 Grounding concept, 27 251 Index Grounding harness, 186 Grounding point, 98 High voltage after shutdown, 186 Insufficient grounding, 89, 104 Make-proof grounding switch, 38, 188 Make-proof grounding switch, motor operated, 64 Protective ground conductor, 27 Shield busbar, 27 Shield connection, 98 I IGCT Integrated Gate Commutated Thyristor, 36 L LEDs DM10 diagnostics module), 177 Power Stack Adapter, 176 M Make-proof grounding switch Function, 38 Line side, motor operated, 64 Motor side, motor operated, 64 Monitoring Communication between the closed-loop control and power unit, 33 Failure of the control components, 33 Internal protection functions for the control hardware, 33 Make-proof grounding switch, 64 Monitoring functions and protective devices, 28 Residual current monitor, 23 Semiconductor failure, 33 Shock and tilt indicators, 72 Wire breakage, 241 Monitoring systems, 32 More information, 229 Motor Module, 33 O On-site service, 229 Parameter types, 152 Phase module Replacing, 204 Power Stack Adapter Actual value acquisition, 240 Function, 40 Internal fuse, 242 Precharging Components, 38 Function, 37 Replacing the precharging transformer, 216 PROFIBUS connection PROFIBUS, 110 Protection and monitoring functions External components, 33 Internal components, 32 PSA Power Stack Adapter, 36 R Rated output frequency Sine-wave filter, 69 Re-cooling unit Deionized water, 22, 53, 54, 92 Deionized water specifications, 54 Inadmissible additives, 54 Principle of operation, 53 Raw water, 53 Requirements, 53 S Safety information Connecting the transportation units, 88 Securing the cabinet to the floor, 88 Shock and tilt indicators Location, 73 Purpose, 72 Spare parts, 229 Contact person, 225 Spares On Web, 225 Speed limitation, 155 Storage Drive unit, 83 General specifications, 83 Preconditions, 83 Storage duration, 84 P Parameter categorization, 152 252 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Index T Technical specifications dv/dt filter, 60 Filter resistor, 62 Technical Support, 229 Transformer Input side, 32 V Voltage source DC link, 38 W Water condensation, 66 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 253 Index 254 SINAMICS GM150 6SL3835-2LN44-2AA0 Operating Instructions 04/2017 Further Information www.siemens.com/drives Siemens AG Process Industries and Drives Postfach 48 48 90026 NURNBERG GERMANY