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Siemens 6SL38502UM114PA0Z, Operating Instructions & Installation Instructions

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Siemens 6SL38502UM114PA0Z Operating Instructions & Installation Instructions Download Page 127

9.7.10

Replacing the DC-link reactor

Establishing and grounding the power connections

The power connections are made by the expansion straps. To establish and ground the power 

connections, proceed as follows:
1. Clean and grease the contact surfaces immediately before screwing in the connections.

For this purpose, use the cleansing agents and greases listed in the table below.

Medium

Description

Cleaning agent

Ethyl alcohol and lint-free cloth

Grease

Electrolube 2G or equivalent contact lubricant

2. Screw in the connections. The tightening torque of the M12 screw connections supplied is 

50 Nm.

3. Ground the DC link reactor by the cabinet grounding cable.

Maintenance

9.7 Repairs

SINAMICS GL150 6SL38502UM114PA0Z

Operating Instructions Rev.201910281441  EXAMPLE

127

Summary of Contents for 6SL38502UM114PA0Z

Page 1: ...www siemens com drives Medium Voltage Drive SINAMICS GL150 Type 6SL38502UM114PA0Z Operating Instructions Installation Instructions Edition 10 2019 This documentation pertains to EXAMPLE ...

Page 2: ...28 10 2019 14 41 V18 00 ...

Page 3: ...tructions This documentation pertains to EXAMPLE Edition 10 2019 Introduction 1 Safety information 2 Description 3 Preparations for use 4 Mounting 5 Electrical connection 6 Commissioning 7 Operation 8 Maintenance 9 Spare parts 10 Disposal 11 Service Support A Technical specifications and drawings B ...

Page 4: ...ose 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...

Page 5: ...ection in electromagnetic fields 23 2 8 Residual risks 23 2 9 Security information 25 3 Description 27 3 1 Area of application 27 3 2 Safety concept 27 3 2 1 External safety components 28 3 2 2 Protection and monitoring functions of internal components 28 3 2 3 Protection and monitoring functions for external components 29 3 3 Power unit 29 3 3 1 Power unit components 29 3 3 1 1 Design of the thyr...

Page 6: ...idity controlled anti condensation heating option L58 43 3 5 13 Dust protection option M11 43 3 5 14 Lock barrel option M40 43 3 5 15 Degree of protection IP41 option M41 43 3 5 16 Separate installation M49 43 3 5 17 Low noise fan option M65 43 3 5 18 Customer specific door stop for control cabinets option M76 44 3 5 19 Line side surge arresters option N54 44 3 5 20 Machine side surge arresters op...

Page 7: ...oring fans 65 5 Mounting 67 5 1 Safety instructions for installation 67 5 2 Tools required 68 5 3 Torques 68 5 4 Screwing the transport units together 69 5 5 Connect to the foundation 70 5 6 Mounting fans 70 5 7 Ensuring cooling air 71 6 Electrical connection 73 6 1 Safety instructions for electrical connection 73 6 2 Note on shielded cables 75 6 3 Electromagnetic compatibility 75 6 4 Potential co...

Page 8: ... of the converter 94 8 4 2 Speed monitoring with incremental encoder 94 8 4 3 Uncontrolled stop EMERGENCY STOP category 0 94 8 5 Fault and system messages 95 8 5 1 External warnings and faults 96 8 5 2 Diagnostics 96 8 5 2 1 Diagnostics via LEDs 96 8 5 2 2 Diagnostics via parameters 97 8 5 2 3 Indicating and rectifying faults 100 9 Maintenance 101 9 1 Safety instructions for maintenance 101 9 2 Gr...

Page 9: ...urge arresters 126 9 7 10 Replacing the DC link reactor 127 10 Spare parts 129 11 Disposal 131 11 1 Disposing of packaging material 131 11 2 Removing device components and old devices 131 A Service Support 133 A 1 Siemens Industry Online Support 133 A 2 SIOS App 134 B Technical specifications and drawings 135 B 1 Standards and regulations 135 B 2 Environmental conditions 136 Index 139 Tables Table...

Page 10: ...control 51 Figure 4 3 Laying cables 52 Figure 4 4 Example of attaching and displaying the shock and tilt indicators 55 Figure 4 5 Example illustration of centers of gravity 57 Figure 4 6 Lifting bar label 59 Figure 4 7 Securing the lifting rods 59 Figure 4 8 Transporting a transportation unit still in packaging with a crane 61 Figure 4 9 Example Cover screw for manual door interlocking 63 Figure 5...

Page 11: ...ure 9 5 Example of an AVT combination module 116 Figure 9 6 Line side fuse 119 Figure 9 7 Thyristor rack position 121 Figure 9 8 Thyristor replacement 124 Figure 9 9 Releasing a fiber optic cable 126 Table of contents SINAMICS GL150 6SL38502UM114PA0Z Operating Instructions Rev 201910281441 EXAMPLE 11 ...

Page 12: ...Table of contents SINAMICS GL150 6SL38502UM114PA0Z 12 Operating Instructions Rev 201910281441 EXAMPLE ...

Page 13: ...of other persons and to avoid material damage carefully follow these instructions when carrying out any work If you have suggestions for improving the document please contact our Service Center Page 133 1 2 Text format features Text format features You can find the following text format features in these instructions 1 Handling instructions are always formatted as a numbered list Always perform th...

Page 14: ...Introduction 1 2 Text format features SINAMICS GL150 6SL38502UM114PA0Z 14 Operating Instructions Rev 201910281441 EXAMPLE ...

Page 15: ...n 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 5 safety rules Fo...

Page 16: ...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 converter properly Always observe the The five safety rules Page 15 when carrying out any work Only remove the covers using the methods described by these operating instructions Maintain the...

Page 17: ... maximum permissible input currents are listed in the Technical specifications Remove contamination and dirt After installation and mounting carefully check that no objects have been left in the device Danger due to live stationary parts moving or rotating parts Contact with the parts mentioned can result in death serious physical injury or damage to property Observe the instructions regarding ins...

Page 18: ...monitoring device If you use a residual current monitoring device RCD it is possible that the residual current monitoring device will trip in error nuisance trip The converter 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...

Page 19: ...ents 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 packagin...

Page 20: ... 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 Explosions If you operate the device in a hazardous zone explosions can occur which can cause death serious injuries or material damage Never operate the device in an explosive atmosphere hazardous zone Non o...

Page 21: ...rate 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 integr...

Page 22: ...tenance and access by unauthorized persons can lead to accidents The results can be death serious bodily injury or damage to property Install the device 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 b...

Page 23: ...omagnetic 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 Residua...

Page 24: ...re errors Operating and or environmental conditions outside of the specification External influences damage For instance a fault can have the following effects Extraordinarily high temperatures including open fires as a result of the fault Emissions of light noise particles or gases Devices with Open Type IP20 degree of protection must be installed in an electrical room or a comparable environment...

Page 25: ...etworks 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 ...

Page 26: ...w de view 109751848 en Security Guidelines for SIMATIC HMI devices Manual Notes relating to Industrial Security for HMI devices are available here https support industry siemens com cs de en view 109481300 Safety information 2 9 Security information SINAMICS GL150 6SL38502UM114PA0Z 26 Operating Instructions Rev 201910281441 EXAMPLE ...

Page 27: ...e sets Hydroelectric power generators Large synchronous motors on weak power systems Continuous duty converter The output frequency typically lies between 0 and 105 Hz The converter is used for the variable speed drive of the following driven machines for example Blowers Fans Pumps Turbo compressors Reciprocating compressors Extruders and mixers Continuous flow conveyors Marine propellers Drive in...

Page 28: ...tected the medium voltage transformer limits the short circuit current and is configured in such a way that the maximum permissible short circuit current see the technical data is not exceeded 3 2 2 Protection and monitoring functions of internal components The internal components of the converter have the following protection and monitoring functions Converter protection based on monitoring syste...

Page 29: ...r Air cooled DC link reactor installed in a cabinet Motor side converter Machine side voltage sensing VM sensing Current transformer in the DC link Converter transformer Synchronizing transformer or converter Line side voltage detection optional Figure 3 1 Power unit components of the starting converter 6 pulse drive system 3 3 1 1 Design of the thyristor stack A thyristor stack is used for a 6 pu...

Page 30: ...tor stack Each thyristor is connected with a resistor and a capacitor The resistor and capacitor have the following tasks Where there are several thyristors in series the resistor and capacitor split up the supply voltage equally If the thyristors are switched off the resistor and capacitor limit the rate of voltage rise and voltage overshoot A thyristor electronics module is assigned to each thyr...

Page 31: ...1 4 AVT combination module The AVT combination module Actual Value Transmission processes signals for sensing the actual current and voltage values The AVT combination module converts analog signals into digital signals Then the module transfers the signals to the Power Stack Adapter PSA The signals are transferred to the PSA via fiber optic cables Figure 3 3 AVT combination module See also Voltag...

Page 32: ...status of the thyristor and relays it to the Power Stack Adapter via the checkback fiber optic cable The control commands and checkback signals correlate with each other Any disruption to this relationship for example an open circuit in an FO conductor or a failed thyristor is relayed to the open loop closed loop control system as an error message 3 3 1 6 Current transformer Current transformers a...

Page 33: ...input terminals should be ensured by an appropriate transformer design In addition the converter requires matched circuit breakers with a tripping time of 80 ms The closed loop control system triggers the circuit breakers Each circuit breaker must be equipped with a fail safe OFF contact and an undervoltage coil Internal current transformers sense the current and evaluate it electronically The ope...

Page 34: ...miconductors is selected so that after a short circuit current the thyristors still have sufficient blocking ability in accordance with the figure shown below Short circuiting sequence The converter can cope with virtually any incident using the fuseless technology and will switch itself off W X N LN 8 L 6KRUWHG FLUFXLW Figure 3 5 Short circuiting sequence 3 3 2 2 Thyristor electronics Gate contro...

Page 35: ...end these checkback signals back to the Power Stack Adapter The Power Stack Adapter evaluates these status checkback signals from the thyristor electronics With the Thyristor in command window status checkback signal and the synchronizing voltage the offset angle can be determined in a test operation The information that can be derived from the correlation between the command and the generated sig...

Page 36: ...y Figure 3 6 Voltage sensing components AVT combination modules Transformer Measuring resistors 80 kHz power supply Figure 3 7 Overview of the voltage sensing circuit Description 3 3 Power unit SINAMICS GL150 6SL38502UM114PA0Z 36 Operating Instructions Rev 201910281441 EXAMPLE ...

Page 37: ...ostatically controlled and is switched on when the temperature inside the cabinet reaches approximately 40 C The air is drawn in through the lower door filter and blown out using the fan 3 4 2 Mushroom pushbutton The mushroom pushbutton is used for safety shutdown When the safety shutdown function is actuated the converter shuts down with a fault and a corresponding message appears on the display ...

Page 38: ...ol module of the drive s open loop and closed loop control system The connections are wired internally to the customer terminal block 3 4 3 2 DRIVE CLiQ interface Table 3 1 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 Receive data 7 Reserved do not use 8 Reserved do not use A 24 V Po...

Page 39: ...rating state and the function 3 5 Options 3 5 1 Internal synchronizing voltage detection option A11 The internal synchronizing voltage detection is used to measure the line voltage See also Voltage actual value sensing Page 35 3 5 2 Damping switch for 1 4 kV option C50 The damping circuit includes a rectifier circuit with RC circuit The damping circuit is connected to the output of the starting co...

Page 40: ... the SFC nominal power or current at Ug Un SFC Operating time min Ventilation 70 0 Pause 0 0 1 Normal start 100 4 Pause 0 2 5 Ventilation 70 0 Pause 0 0 2 Normal start 100 4 Pause 0 2 5 Ventilation 70 0 Pause 0 0 3 Normal start 100 4 Pause 0 2 5 Ventilation 70 0 Pause 0 0 4 Normal start 100 4 Non operational period 0 120 It can be derived from the load cycles that the starting frequency converter ...

Page 41: ...onnection between the starting converter and excitation equipment option G57 Three plug connections are provided in the cutout in the side panel This is used to connect the power unit of the starting converter with the open loop control cabinet of the excitation equipment The sockets are permanently installed in the open loop control cabinet side panel The corresponding connectors in the converter...

Page 42: ...specific points in the starting converter transformer using PT100 resistance thermometers Normally the three windings and the middle leg of the transformer are monitored A pre alarm and a limit temperature are monitored as digital signals 3 5 9 Control Unit CU320 2 PN option K95 The CU320 2 PN Control Unit allows the bus to be connected to the higher level control unit using the PROFINET protocol ...

Page 43: ... of dust in the filter mats When the differential pressure switch responds a fault message is output and the converter is switched off 3 5 14 Lock barrel option M40 The cabinet interlocking is equipped with locking cylinders All cabinets in the plant must have the same locking cylinder 3 5 15 Degree of protection IP41 option M41 The degree of protection is increased to IP41 3 5 16 Separate install...

Page 44: ...tage peaks on the motor side and prevents overvoltages Overvoltages can occur when inductive loads are switched for example when a transformer is switched off when it has no load connected to its secondary These overvoltages can pose a danger to the converter For indoor systems surge arresters without spark gap are used to limit the overvoltages They are connected between the phases in a star conf...

Page 45: ...24 Customized duty cycle option Y45 The customer specific load cycle is included in the converter Description 3 5 Options SINAMICS GL150 6SL38502UM114PA0Z Operating Instructions Rev 201910281441 EXAMPLE 45 ...

Page 46: ...Description 3 5 Options SINAMICS GL150 6SL38502UM114PA0Z 46 Operating Instructions Rev 201910281441 EXAMPLE ...

Page 47: ...cuit and simultaneous failure of the closed loop control system are dangerous if the transformer configuration is incorrect This can result in death serious injury or material damage When selecting and dimensioning the transformer observe the notes regarding the short circuit behavior for fuseless technology in Chapter Fuseless technology Page 33 As well as adjusting the input voltage of the conve...

Page 48: ...lts in a deformation of the supply voltage for subsequent windings This can cause a malfunction in the case of controlled line side converters In critical cases ensure that the degree of coupling is less than 10 to 15 and that the degree of decoupling is between 85 and 90 Design of the transformer winding Core Figure 4 1 Two tier design Transformers for start up operation For short time operation ...

Page 49: ... The circuit breaker must be equipped with an undervoltage release The undervoltage release undervoltage release coil is controlled via the release circuit into which the undervoltage release output of the converter must be integrated as well The auxiliary voltage from the switchgear this is a reliable supply is used as the supply Note In power converters the undervoltage release is not normally s...

Page 50: ...input of the converter The second tripping contact is wired to the undervoltage release of the circuit breaker The voltage at the undervoltage coil is queried via an optocoupler The output of the optocoupler is wired to the leading contact input of the converter We recommend using a Phoenix ST OE 3 optocoupler with 24 V short circuit proof DC voltage output The exact type will depend on the auxili...

Page 51: ...ZLWFKJHDU V VWHP PXVW EH VSHFLILHG ZKHQ RUGHULQJ WKH FRQYHUWHU 3 6 VWHP VLGH WULSSLQJ FRQWDFWV 4 RU GHWDLOV VHH FLUFXLW GLDJUDP B6 MSR B6 MSR SM 2 3 kV bis 36 kV 3 50 60 Hz 1 8 2 3 165 165 4 Figure 4 2 Example Circuit breaker control Preparations for use 4 1 Notes for system integrators SINAMICS GL150 6SL38502UM114PA0Z Operating Instructions Rev 201910281441 EXAMPLE 51 ...

Page 52: ...ass The converter can run even if a ground fault is present In this case the voltage to ground is the line to line voltage 4 Where the current is concerned take into account the rms value for dimensioning purposes as the rms value also contains the harmonic currents Cable capacitance and inductance Cable capacitances and inductances can influence the commutation The cable capacitance has an influe...

Page 53: ...dard for cabling the power unit static excitation equipment and closed loop control The cable related cabinet distances can be specified for the project Shield support Observe the notes in Chapter Connecting the power unit Page 81 Reference Heinold Lothar publ Kabel und Leitungen für Starkstrom I Publicis Corporate Publishing 1987 4 2 Requirements when mounting and installing the device 4 2 1 Requ...

Page 54: ...mmissioning 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...

Page 55: ...ion 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 dropp...

Page 56: ...opriate 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 For lifting the device always use certified and adequately dimensioned cable guiding and spreading devices that are in absolutely ...

Page 57: ...YLHZ 6LGH YLHZ Figure 4 5 Example illustration of centers of gravity 4 4 4 Transport with a fork lift truck WARNING Danger when a transport unit cabinet tips over If the forks are too short this can cause the transport unit cabinet to tip over resulting in death serious injury or damage to the cabinet The forks of the truck must protrude at the rear of the transport pallet The floor panels of the ...

Page 58: ...apacity 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 4 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 devic...

Page 59: ...igure 4 6 Lifting bar label 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 7 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 ...

Page 60: ...sportation with the crane WARNING Danger due to falling transport unit cabinet If the lifting gear or load suspension devices were to fail the transportation unit the cabinet could fall Death serious injury or material damage can result Do not stand underneath or near to a raised load To protect the boxes against pressure use sufficiently long rope and a spreader beam Please proceed as follows 1 A...

Page 61: ...TICE 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 w...

Page 62: ...n 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 secur...

Page 63: ...move the nuts of the upper mounting bolts last of all 3 Remove the cover 4 5 6 Checking the shock and tilt indicators inside the cabinet Shock and tilt indicators are also located inside the cabinet Check these as soon as you have unpacked and opened the device To perform the check proceed as described in Checking shock and tilt indicators NOTICE Material damage caused by transport indicators rema...

Page 64: ...ust 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 su...

Page 65: ... 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 4 6 2 Storing fans NOTICE Improper fan storage Even if the fan is not used the bearing grease ages The utility of the fan can be...

Page 66: ...Preparations for use 4 6 Storage SINAMICS GL150 6SL38502UM114PA0Z 66 Operating Instructions Rev 201910281441 EXAMPLE ...

Page 67: ...ous injury and material damage 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 Danger due to defective seals When working on the device seals at the doors roof panels as well as front rear and side panels ca...

Page 68: ... 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 1 Examples of soft materials are Cu Al CuZn cable entries laminate materials plastics cast resin post insulators press nuts welding nuts blind rivet nuts and cage nuts 2 Hard materials S2 are materials with friction enhancing washer components e g a contact washer 3 Hard S1 m...

Page 69: ...ccurs during transport may exert mechanical pressure on the components Material damage can result Line the cabinets up precisely with each other in order to avoid shearing forces when the base units are screwed together Install the converter only on a level and horizontal surface Ensure that access to the holes in the bottom of the cabinets is unobstructed Remove the guard covers Mounting hardware...

Page 70: ...inet panel to secure the cabinet to the foundation Information on mounting holes and their fixing dimensions are specified in the dimension drawing Install the transport units in accordance with the specifications provided in the accompanying dimension drawings When doing this maintain the specified distance between the top of the cabinet and the ceiling 5 6 Mounting fans You must mount the fans i...

Page 71: ...e perforated top cover or the ventilation grilles in the top cover Make sure that the air that is supplied is free of dust or any other electrically conductive material Avoid environmental conditions that could cause condensation Seal the cable connector panels from the top Mounting 5 7 Ensuring cooling air SINAMICS GL150 6SL38502UM114PA0Z Operating Instructions Rev 201910281441 EXAMPLE 71 ...

Page 72: ...Mounting 5 7 Ensuring cooling air SINAMICS GL150 6SL38502UM114PA0Z 72 Operating Instructions Rev 201910281441 EXAMPLE ...

Page 73: ...th serious injury and material damage To maintain the degree of protection after connecting the cable immediately seal the cable entries so they are air tight Danger caused by changing the floor panel or the 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 mean that the requirements related to the specified degree of protect...

Page 74: ...nnect the cables between the cabinets use the cable ducts and the cable entries on the roof Lead the cables from here to the next cabinet Material damage caused by parts that can be magnetized The use of magnetizable parts e g ferrous cable clamps is not permitted Using parts and components that can be magnetized can cause damage Only use parts that consist of non magnetic material Material damage...

Page 75: ...y 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 6 3 Electromagnetic compatibility The following fundamental information and guidelines facilitate compliance with the EMC directives Note We recommend that EMC is planned for the entire plan...

Page 76: ...es 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...

Page 77: ...e 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 Bridging shield gaps Electrical con...

Page 78: ... or exiting via the cable filter auxiliary voltages in the control cabinet 6 4 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 QWHUQDO ORDGV WHUQDO ORDGV 3 0 3 0 1 Figure 6 3 ...

Page 79: ...HG WR WKH YHUWLFDO FDELQHW 7R RWKHU V VWHP FRPSRQHQWV TXLSRWHQWLDO EXVEDU 6KLHOGLQJ EXV 6HUUDWHG EXVEDU RQWURO V VWHP 3RZHU FRPSRQHQWV 7HUPLQDO EORFN Figure 6 5 Equipotential bonding strip 6 7 Connecting the protective grounding Connect the protective grounding to the cabinets and components in the system via the PE conductor Use the ground clamps for this or the special terminal provided for the ...

Page 80: ...ielding Connect the cable shields at both ends to the shield rails in the cabinets Always use shielded analog signal cables regardless of whether they are installed inside or outside cabinets In order to increase the effectiveness of the shielding ground spare conductors at both ends 6 9 Laying the cable shields In the case of analog signal lines carrying small signals mV or µA attach the cable sh...

Page 81: ...the cable shields only to the transformer or the motor away from the converter 0 ᅚ ᅜ ᅚ ᅜ ᅜ ᅚ ᅚ ᅜ Circuit breaker Connect shield Line side transformer X Do not connect shield Converter Machine side transformer Motor Figure 6 6 Shield support Separately route back additional equipotential bonding conductors to the converter The cross section of this conductor must be at least as large as the total c...

Page 82: ...r panel Chips in the converter shorten clearances and creepage distances and can lead to flashovers Cut out the floor panel outside the area of the converter Take care that no metal chips are left in the converter Protect cut edges to prevent damage to the cable insulation 2 Make the connection between the supply and the converter and between the converter and the motor with the required number of...

Page 83: ...Adapter in the electronics compartment of the power unit The signal traffic to the open loop and closed loop control cabinet is handled via these interchange points The terminal blocks are used to wire up the following Signals Auxiliary voltage for fans and anti condensation heating systems Power supply for the electronics Procedure To connect the signal lines proceed as follows 1 Connect the sign...

Page 84: ...mmediately 6 13 2 Connecting the auxiliary voltage Connect the auxiliary voltage e g for SITOP to the terminal block The maximum cross section of the cables is 2 5 mm2 You will find detailed information in the terminal diagram or in the circuit manual under Technical specifications and drawings See also Technical specifications and drawings Page 135 6 13 3 Connecting circuit breakers To connect th...

Page 85: ...re that the drive stops immediately nor can it ensure that residual voltages do not still exist at the output terminals and within the unit Make sure that the drive no longer rotates and that there are no high voltages present Procedure To connect the external safety loop proceed as follows 1 Switch off the converter 2 Remove the jumper over the terminals inserted in the factory that you wish to u...

Page 86: ...able ties around the entire cable duct The cable ties must be located at the same positions as in the delivered state Figure 6 8 Schematic diagram Fastening the cable ties Electrical connection 6 15 Fastening the cable ducts with cable ties SINAMICS GL150 6SL38502UM114PA0Z 86 Operating Instructions Rev 201910281441 EXAMPLE ...

Page 87: ...ous injury or material damage Incorrectly performed commissioning can result in the warranty becoming null and void It is not permissible to commission the device if it is dirty Immediately contact Customer Support You can find the relevant contact person under Service Support This device may only be commissioned by electrically skilled persons who have been adequately trained on this product and ...

Page 88: ...Commissioning SINAMICS GL150 6SL38502UM114PA0Z 88 Operating Instructions Rev 201910281441 EXAMPLE ...

Page 89: ...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 Immediately switch off the device if a ground fault occurs during operation Then identify and eliminate the source of the ground fault The company operating the plant or system is responsible for the consequences ...

Page 90: ...via PROFIBUS Operator panel 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 UHDG ZULWH S ...

Page 91: ...n 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 8 3 Setpoint channel and closed loop control 8 3 1 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 This can be carried ...

Page 92: ...eeds the bands are assigned a hysteresis Specify a minimum speed in order to block a specific range around the stopped state for stationary operation 8 3 4 Speed limitation Speed limitation can limit the maximum permissible speed of the entire drive train to protect the drive and load machine process against damage caused by excessive speeds 8 3 5 Ramp function generator The ramp function generato...

Page 93: ...s to facilitate an improved control response Short settling times for load changes to facilitate an improved response to disturbances Acceleration and braking are possible with the 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...

Page 94: ...till exist at the output terminals and within the unit Make sure that the drive no longer rotates and that there are no high voltages present 8 4 2 Speed monitoring with incremental encoder Permanent speed monitoring enables motor control without an encoder If higher performance applications require permanent speed monitoring additional incremental encoders can be connected to options A51 A54 High...

Page 95: ... to the terminal block EMERGENCY STOP button Where connected DB S1001 31 32 EMERGENCY STOP customer DB X05 9 10 Max connectable cross section 4 mm AWG 10 Activation of the circuit breakers is described in the section entitled Connecting the circuit breakers 8 5 Fault and system messages Hardware trace The drive saves data to the CompactFlash card each time there is a fault trip Customer Supports r...

Page 96: ...ot actuated Open Fault Relay jammed Motor contactor jammed Defect in electronics Open Cross circuit ground fault in EMERGENCY STOP circuit no supply voltage LEDs of the Power Stack Adapters Table 8 2 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 If input voltage is 18...

Page 97: ...nge or Red orange Flashing light Component recognition via LED is acti vated The color depends on the LED state when component recognition is activated 8 5 2 2 Diagnostics via parameters Diagnostic parameters for the device status See the List Manual for a description of the individual parameters r0002 Drive status DO Display of drive status VEKTORGL r0046 Missing enable signal DO Displays missing...

Page 98: ...en into account It does not matter whether DI DO is set as an input or output p4028 r4022 Status of digital inputs on TM15 Module Displays the status of the digital inputs of Terminal Module 15 TM15 TM15 r4047 Status of digital outputs on TM15 Module Displays the status of the digital outputs of Terminal Module 15 TM15 TM15 It does not matter whether DI DO is set as an input or output p4028 R6580 ...

Page 99: ... the fault occurred All objects r0949 Fault value DO Displays additional information about the fault that occurred as integer number All objects r2122 Counter alarm buffer changes DO This counter is incremented every time the alarm buffer changes All objects r2123 Alarm time received in milliseconds DO Displays the system runtime in milliseconds when the alarm occurred All objects r2124 Alarm valu...

Page 100: ...nverter from damage in the event of a fault faults and alarms A list of faults and alarms with remedies for their rectification can be found in the List Manual in the faults and alarms chapter Operation 8 5 Fault and system messages SINAMICS GL150 6SL38502UM114PA0Z 100 Operating Instructions Rev 201910281441 EXAMPLE ...

Page 101: ...a result of high voltages from external supplies Magnetizing and demagnetizing equipment that is fed from an external voltage source can result in high voltages This voltage can result in death or serious injury Ensure that no voltage from external feeds exists before commencing maintenance and repair work Danger due to high voltages of the snubber circuit capacitors The snubber circuit capacitors...

Page 102: ... 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 Damage due to non authorized spare parts Using non approved spare parts can affect the function of the equipment and damage it Third party spare parts and unapproved spare parts may not meet the requirements Only use spare parts that ...

Page 103: ...ty analysis 9 2 Grounding the system WARNING Danger due to high voltage after shutdown High voltages can still be present even after shutdown Touching the device can result in death or serious injury Only work on the power unit if it has been sufficiently grounded Before touching the device carefully ensure that the following parts of the power unit are de energized and are in a no voltage conditi...

Page 104: ...evice To remove the covers from the power unit proceed as described in Chapter Removing the cover Page 63 Once you have performed any maintenance measures carry out the following steps before you mount the covers again 1 Check the seals between the cabinet and the covers for damage If these is any damage replace the seals 2 Replace the contact washers 3 Mount the covers in the reverse order to whi...

Page 105: ...lean if required Check power and control con nections Operating company After one year and ev ery four years thereafter Check internal connections Siemens serv ice personnel After one year and ev ery four years thereafter Carry out an inspection and visual check Siemens serv ice personnel Annually See the specifications in the Operating Manual Check the software Siemens serv ice personnel After ev...

Page 106: ...ibed maintenance intervals into consideration as well as the instructions for repairing and replacing installed components 9 4 1 2 Checking the isolating clearances Slight dry non conducting contamination is permitted Remove contamination caused by dust in conjunction with high humidity See also Cleaning Page 113 9 4 1 3 Checking hoisting solenoids and security bolts Check the hoisting solenoids a...

Page 107: ...heck whether the components are showing signs of failure Examples of failure symptoms Irreparable damage Traces of smoke Scorching Check the circuit boards with regard to the following criteria Interruptions Short circuits Minimum clearances Traces of smoke Scorching See also Cleaning Page 113 9 4 1 7 Checking the filter mats Check the air filters in the cabinet doors for pollution Clean the filte...

Page 108: ...n 1 Disconnect the equipment 2 Switch off the motor protection switch 3 Remove the mesh cover on the junction box side of the fan To do this remove the seven screws of the mesh cover 4 Open the cover of the junction box and remove the fan cables 5 The fan is attached to the roof section using four nuts which are located inside the fan Remove the four nuts including the contact washers If required ...

Page 109: ...ose the cover of the junction box 5 Attach the mesh cover Tighten the screws with the specified torque The torque for the countersunk head screws is 4 5 Nm The torque for the hex screws is 10 Nm Removing the fan Follow the five safety rules before replacing the fans NOTICE Damage caused by insufficient cooling Cooling is only ensured if the fan is rotating in the correct direction When you are ins...

Page 110: ...out of the converter more easily CAUTION Injury due to a falling fan The fans are very heavy 50 kg If incorrectly handled fans can fall and result in injury and material damage Please take special care when removing the fans from the converter Installing the fan 1 Insert the new fan 2 Move the fan onto the rear screws Align the fan 3 Insert the front screws M8 Tighten the screws with a torque of 1...

Page 111: ...ds for maintenance personnel due to arcing This can result in death serious injuries or material damage Do not replace filter mats while the converter is operational NOTICE Damage due to dust deposits 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...

Page 112: ... 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 batt...

Page 113: ...leaning NOTICE Damage caused by aggressive cleaning agents Aggressive chemical agents can damage the electronics This can result in malfunction Never use any type of chemical agent or liquid Only remove severe dirt and contamination after prior consultation with service experts for the particular product Use a dry clean lint free ESD cleaning cloth Wipe all external parts of the rack with it Make ...

Page 114: ...heavy metals Use neither brass bronze or steel wire brushes nor cloths or steel wool interwoven with copper wire 9 7 Repairs WARNING Burns caused by inadequate cable insulation Improperly laid or damaged cables and incorrectly attached cable shieldings can heat up in places and cause fires or short circuits wherever they make contact Check whether all the cable shields are intact Insulate damaged ...

Page 115: ...t for repair The relevant address is available from your Siemens contact person Always enclose the following information Type and serial number Time and date of the failure Description of the fault profile Specify what happened when the component failed Operating point currents and voltages Log file with fault messages Copy of the CompactFlash card If possible hard copies from the plotter or scree...

Page 116: ...r optic cables 3 Remove the four fixing screws of the AVT combination module Figure 9 5 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 Maintenance 9 7 Repairs SINAMICS GL150 6SL38502UM114PA0Z 116 Operating Instructions Rev 201910281441 EXAMPLE ...

Page 117: ...electronics Use heat stabilized cable ties for fixing the capacitors in place Tighten the capacitor terminals with the following torques Table 9 2 Torques of the capacitor connections Nuts Tightening torque M8 5 Nm M12 10 Nm 9 7 3 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...

Page 118: ...ithdraw the air hose at the differential pressure monitor 4 Release the two screws that are used to attach the differential pressure monitor 5 Release the differential pressure monitor from the mounting plate 6 Attach the new differential pressure monitor to the mounting plate 7 Reinstall the new differential pressure monitor in the cabinet Reconnect the cables and air hose 8 After replacing the d...

Page 119: ... the fault 5 Install the replacement fuses 6 Close the cabinet 9 7 6 Replacing contactors CAUTION Injury when using incorrect contactors Use of the wrong contactor can result in a malfunction and thus lead to physical injuries and material damage Always use contactors of the same type Check the device numbers of the previous and new contactors To replace the contactors proceed as follows 1 Loosen ...

Page 120: ...transformer from the cabinet See also The 5 safety rules Page 15 Installing the current transformer To install the current transformer proceed as follows 1 Carry out the removal steps in reverse order 2 Screw the screws into the busbars with a tightening torque of 25 Nm 3 After installing the current transformer check that it works properly 9 7 8 Replacing the thyristor electronics and thyristors ...

Page 121: ...ed via a circuit in the thyristor electronics This circuit is interrupted when the thyristor electronics are withdrawn Voltages of up to several 1000 V can occur and cause an electric shock This can result in death severe injuries and significant material damage In this case you should treat the capacitors as if they were charged Discharge the snubber circuit capacitors Short circuit the snubber c...

Page 122: ...e thyristor electronics To change the thyristor electronics proceed as follows 1 Take out the thyristor electronics To do this loosen the four screws with which the thyristor electronics are fixed to the carrier frame 2 Send the defective thyristor electronics back Refer to Notes on sending back Page 123 to help you 3 Install the new thyristor electronics Tighten the screws with a tightening torqu...

Page 123: ...information about the damage to the thyristor electronics will be helpful for determining the cause of the fault and for repair Moreover this data is evaluated for a reliability analysis Include information about the most recent operational performance and about any previous conspicuous behavior See also Components that can be destroyed by electrostatic discharge ESD Page 19 9 7 8 3 Replacing a th...

Page 124: ...tack provides the necessary pressure Removing a thyristor M8 fixing screw 2 x M12 fixing screws on the underside M20 nuts for the clamping device Groove of the guide bolt A5E00291256 open ended wrench Figure 9 8 Thyristor replacement 1 Detach the gate lead from the thyristor electronics 2 Insert the open ended wrench into the groove of the guide bolt 3 Remove the fixing screw 4 Loosen the fixing s...

Page 125: ...amping pressure plates show the appropriate information 5 Tighten the nuts evenly and in small increments max 1 4 turn per increment After each increment check whether the open ended wrench can be removed As soon as the open ended wrench can be removed the clamping force is correctly set The inner side of the groove of the steel bolt can be used as an additional check When the clamping force is co...

Page 126: ...c cables proceed as follows 1 Carefully unscrew the knurled nut 2 Pull the fiber optic cable out 3 Insert the new fiber optic cable as far as it will go If correctly fitted the white ID ring must be flash with the opto transmitter or opto receiver 4 Tighten the knurled nut again by hand 9 7 9 Replacing surge arresters To replace the surge arrester proceed as follows 1 Release the screws 2 Remove t...

Page 127: ...e connections For this purpose use the cleansing agents and greases listed in the table below Medium Description Cleaning agent Ethyl alcohol and lint free cloth Grease Electrolube 2G or equivalent contact lubricant 2 Screw in the connections The tightening torque of the M12 screw connections supplied is 50 Nm 3 Ground the DC link reactor by the cabinet grounding cable Maintenance 9 7 Repairs SINA...

Page 128: ...Maintenance 9 7 Repairs SINAMICS GL150 6SL38502UM114PA0Z 128 Operating Instructions Rev 201910281441 EXAMPLE ...

Page 129: ...r of the spare part required You can find the order number as follows The device label is attached to or next to each component Find out which item code the required spare part has The parts list provided specify the part number and where appropriate the article number corresponding to the equipment identifier For inquiries by e mail if possible send a photograph of the product spare part rating p...

Page 130: ...Spare parts SINAMICS GL150 6SL38502UM114PA0Z 130 Operating Instructions Rev 201910281441 EXAMPLE ...

Page 131: ... 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 d...

Page 132: ... PCBs Electronic components Disposal 11 2 Removing device components and old devices SINAMICS GL150 6SL38502UM114PA0Z 132 Operating Instructions Rev 201910281441 EXAMPLE ...

Page 133: ...e 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 data base www siemens com yourcontact www siemens com yourcontact SINAMICS GL15...

Page 134: ...executing a project Troubleshooting when faults develop Expanding a system or planning a new system Further you have access to the Technical Forum and other articles that our experts have drawn up FAQs Application examples Manuals Certificates Product announcements and many more The app is available for Apple iOS Android and Windows Phone Service Support A 2 SIOS App SINAMICS GL150 6SL38502UM114PA...

Page 135: ... only to the extent that it can be applied EU directives Machinery Directive 2006 42 EC amendments Electromagnetic compatibility 2014 30 EU amendments CE marking According to Low Voltage Direction only applies to the low voltage parts e g the control cabinet 2014 35 EU amendments Protection class Class 1 in accordance with DIN EN 61140 VDE 0140 Part 1 IEC 61140 Touch protection BGV A3 Insulation A...

Page 136: ...ding to class 1K3 according to DIN EN 60721 3 1 IEC 60721 3 1 2K2 according to DIN EN 60721 3 2 IEC 60721 3 2 3K3 according to DIN EN 60721 3 3 IEC 60721 3 3 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 a...

Page 137: ...l flora Chemically active substan ces according to class 1C1 according to DIN EN 60721 3 1 IEC 60721 3 1 2C1 according to DIN EN 60721 3 2 IEC 60721 3 2 3C1 according to DIN EN 60721 3 3 IEC 60721 3 3 Mechanically active substan ces according to class 1S1 according to DIN EN 60721 3 1 IEC 60721 3 1 2S1 according to DIN EN 60721 3 2 IEC 60721 3 2 3S1 according to DIN EN 60721 3 3 IEC 60721 3 3 Tech...

Page 138: ...Technical specifications and drawings B 2 Environmental conditions SINAMICS GL150 6SL38502UM114PA0Z 138 Operating Instructions Rev 201910281441 EXAMPLE ...

Page 139: ...cting the signal lines 83 Converter bridge 35 Current conduction permanent signals 35 Current transformer 32 33 Torque 120 D DC link reactor 31 dI dt reactor 42 Differential pressure switch 33 Direction of rotation changeover 91 Door interlock Cover screw 63 Manual 63 Door limit switch 33 DRIVE CLiQ 32 E Electromagnetic fields 18 Environmental conditions 136 F Fan 32 33 Replacing 108 Fiber optic c...

Page 140: ...imes 93 S Safety concept 28 Safety information Failure of a thyristor assembly 120 Fiber optic cables 126 Setpoint addition 91 Shock and tilt indicators Purpose 54 Shock indicator 54 Short circuiting 34 Siemens Industry Online Support App 134 Snubber circuit capacitor 117 Spare parts 133 Contact person 129 Spares On Web 129 Speed limitation 92 Storage Drive unit 64 Fan 65 108 General specification...

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Page 142: ...0009938502 000030 01 EN 01 000993850200003001EN01 000993850200003001EN01 Further Information www siemens com LDA Siemens AG Large Drives Applications Vogelweiherstr 1 15 90441 NÜRNBERG GERMANY ...

Page 143: ...DA EN Tel 49 911 433 6422 Fax 49 911 433 6921 Email motoren doku aud internal siemens co m Our ref 0009938502000030 Date 28 10 2019 Documentation for 6SL38502UM114PA0Z Your order no 4500342954 000030 AL N ECCN N UL DE StWanr CD 85234045 StWanr Print 49011000 Dear Sir Madam Many thanks for your order the documentation for which is enclosed Yours very truly 000993850200003001EN01 ...

Page 144: ......

Page 145: ...r binder 50 mm 120 g m2 SINAMICS GL150 6SL38502UM114PA0Z EXAMPLE Operating Instructions Spine label for binder 145 mm 120 g m2 SINAMICS GL150 6SL38502UM114PA0Z EXAMPLE Operating Instructions Installation Instructions ...

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