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Introduction

1

1.1

About these Operating Instructions

These Operating Instructions describe the device and provide you with information about

handling it - from the initial shipment up to disposal. Keep these instructions for later use.
Read these Operating Instructions and comply with the information provided in them. In this

way you can ensure safe, problem-free operation and a long service life.
Safety information and handling-related warnings are provided in these Operating Instructions.

For your own safety, the safety 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 135).

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 the steps in

the order given.

● Lists are formatted as bulleted lists.

– Lists on the second level are hyphenated.

Note
The note provides you with additional information about the product itself, handling the product

- and the relevant documentation.

SINAMICS GL150 6SL38503UM114PA0Z

Operating Instructions Rev.201910301420 MUSTER

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Summary of Contents for 6SL38503UM114PA0Z

Page 1: ...www siemens com drives Medium Voltage Drive SINAMICS GL150 Type 6SL38503UM114PA0Z Operating Instructions Installation Instructions Edition 10 2019 This documentation pertains to MUSTER ...

Page 2: ...30 10 2019 14 20 V18 00 ...

Page 3: ...structions This documentation pertains to MUSTER 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: ...n 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 Safety components and functions 28 3 2 2 Safety information for IEC 61800 5 28 3 2 3 External safety components 28 3 2 4 Protection and monitoring functions of internal components 29 3 2 5 Protection and monitoring functions for external component...

Page 6: ...on option L05 44 3 5 10 Cabinet anti condensation heating for the power unit option L55 45 3 5 11 Temperature controlled and air humidity controlled anti condensation heating option L58 45 3 5 12 Dust protection option M11 45 3 5 13 Lock barrel option M40 45 3 5 14 Degree of protection IP41 option M41 45 3 5 15 Separate installation M49 45 3 5 16 Low noise fan option M65 46 3 5 17 Customer specifi...

Page 7: ...ock and tilt indicators inside the cabinet 65 4 6 Storage 66 4 6 1 Storing a device 66 4 6 2 Storing fans 67 5 Mounting 69 5 1 Safety instructions for installation 69 5 2 Tools required 70 5 3 Torques 70 5 4 Screwing the transport units together 71 5 5 Connect to the foundation 72 5 6 Mounting fans 72 5 7 Ensuring cooling air 73 6 Electrical connection 75 6 1 Safety instructions for electrical con...

Page 8: ...4 Monitoring and protection functions 96 8 4 1 Safety shutdown of the converter 96 8 4 2 Speed monitoring with incremental encoder 96 8 4 3 Uncontrolled stop EMERGENCY STOP category 0 96 8 5 Fault and system messages 97 8 5 1 External warnings and faults 98 8 5 2 Diagnostics 98 8 5 2 1 Diagnostics via LEDs 98 8 5 2 2 Diagnostics via parameters 99 8 5 2 3 Indicating and rectifying faults 102 9 Main...

Page 9: ... 125 9 7 8 4 Disconnecting the fiber optic cables 128 9 7 9 Replacing surge arresters 129 9 7 10 Replacing the DC link reactor 130 10 Spare parts 131 11 Disposal 133 11 1 Disposing of packaging material 133 11 2 Removing device components and old devices 133 A Service Support 135 A 1 Siemens Industry Online Support 135 A 2 SIOS App 136 B Technical specifications and drawings 137 B 1 Standards and ...

Page 10: ...protection ground fault detection 39 Figure 4 1 Two tier design 50 Figure 4 2 Example Circuit breaker control 53 Figure 4 3 Laying cables 54 Figure 4 4 Example of attaching and displaying the shock and tilt indicators 57 Figure 4 5 Example illustration of centers of gravity 59 Figure 4 6 Lifting bar label 61 Figure 4 7 Securing the lifting rods 61 Figure 4 8 Transporting a transportation unit stil...

Page 11: ...Figure 9 5 Example of an AVT combination module 118 Figure 9 6 Line side fuse 121 Figure 9 7 Thyristor rack position 123 Figure 9 8 Open ended wrench in the groove of the guide bolt 127 Figure 9 9 Loosening the clamping screw with the socket wrench 127 Figure 9 10 Releasing a fiber optic cable 129 Table of contents SINAMICS GL150 6SL38503UM114PA0Z Operating Instructions Rev 201910301420 MUSTER 11 ...

Page 12: ...Table of contents SINAMICS GL150 6SL38503UM114PA0Z 12 Operating Instructions Rev 201910301420 MUSTER ...

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 135 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 t...

Page 14: ...Introduction 1 2 Text format features SINAMICS GL150 6SL38503UM114PA0Z 14 Operating Instructions Rev 201910301420 MUSTER ...

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 th...

Page 17: ...e 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 in...

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 field...

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: ...n 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 ...

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: ...ntenance 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 ...

Page 23: ...romagnetic 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 Residu...

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: ...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...

Page 26: ...ww 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 6SL38503UM114PA0Z 26 Operating Instructions Rev 201910301420 MUSTER ...

Page 27: ...ne 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 i...

Page 28: ...es can still be present even after shutdown If live parts are touched this can result in death or severe injury A grounding switch is not installed The system operator must therefore ensure that there is sufficient grounding Ensure sufficient grounding during work on the power unit Further information on grounding can be found under Safety information for maintenance and repairs See also Grounding...

Page 29: ...are Protection against communication failure between the closed loop control and the power unit Anti condensation heating 3 2 5 Protection and monitoring functions for external components Transformer and motor can be monitored in the device A fast protective shutdown that you can activate for external problems e g short circuits is present 3 3 Power unit 3 3 1 Product features In the standard vers...

Page 30: ... link reactor installed in a cabinet Motor side converter Motor voltage sensing UM sensing Current transformer in the DC link Converter transformer Synchronizing transformer or converter Figure 3 1 Components of a starting converter for a 6 6 pulse drive system 3 3 2 1 Design of the thyristor stack 1 or 2 thyristor stacks are used for a 6 pulse bridge They differ in the number of pick offs from th...

Page 31: ... sink Thyristor Clamping bolt Figure 3 2 Schematic diagram Clamped thyristor assembly The clamped thyristor assembly is pressed together by a set of springs with a clamping screw in such a way as to achieve the required contact force Description 3 3 Power unit SINAMICS GL150 6SL38503UM114PA0Z Operating Instructions Rev 201910301420 MUSTER 31 ...

Page 32: ...reactor The DC link reactor decouples the line side converter from the motor side converter and smoothes the direct current In the event of a fault with overcurrent the DC link reactor limits the rate of current rise with its inductance together with the line reactors Each DC link reactor consists of two magnetically coupled windings wound on an iron core 3 3 2 4 AVT combination module The AVT com...

Page 33: ...onics via fiber optic cables This initiates firing readiness in the thyristor electronics and activates a monitoring and interlocking logic circuit The thyristor electronics then determine the operating 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 rela...

Page 34: ...or example in the case of transformer disconnections at no load These overvoltages can pose a danger to the converter For indoor systems surge arresters without spark gap are connected in a star configuration between the phases to limit the overvoltages 3 3 2 10 Door limit switches Door limit switches monitor the doors or the cover of the power unit When a door or a cover is opened the converter i...

Page 35: ...After that the circuit breaker is opened The leakage reactances of the line transformer or the machine and the supply line from the feeding supply system limit overcurrent in the event of internal short circuits In this case the circuit breaker responds sufficiently quickly to prevent consequential damage If there are control errors on the machine side serious damage to the converter may occur The...

Page 36: ...optical gating pulses and evaluates the feedback signals from the thyristor electronics Mode of operation of thyristor electronics Thyristor electronics are part of the thyristor control system The thyristor electronics receive the control signals from the Power Stack Adapter via fiber optic cables The thyristor electronics module generates the following signals Gate pulses Checkback signals Check...

Page 37: ...onnected in series This ensures a high degree of measuring accuracy AVT combination modules Transformer Measuring resistors Surge suppressor only 3 kV 80 kHz power supply Figure 3 6 Example Components of the motor voltage sensing Description 3 3 Power unit SINAMICS GL150 6SL38503UM114PA0Z Operating Instructions Rev 201910301420 MUSTER 37 ...

Page 38: ...iew of the voltage sensing circuit 3 3 3 4 Ground fault detection The measuring resistors are current limiting elements Using them in conjunction with the surge suppressor provides personnel protection Description 3 3 Power unit SINAMICS GL150 6SL38503UM114PA0Z 38 Operating Instructions Rev 201910301420 MUSTER ...

Page 39: ...eaches 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 of the operator panel Before you restart the converter you must acknowledge the fau...

Page 40: ...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 41: ... used to supply the customer terminals and the circuit breaker 3 4 3 6 Power supply unit A power supply unit is used for the 24 V power supply for the control compartment and the power unit of the starting converter The power supply unit has an input voltage range from 88 350 V DC 3 4 3 7 Sirius safety relay The safety relay monitors the status of the Emergency Off circuit and is used to implement...

Page 42: ...ristor has been switched off 3 5 3 Duty cycle option C61 The starting frequency converter is dimensioned in such a way that the specified duty cycles can be performed The duty cycles are possible with the described operating modes without thermal overload at maximum ambient temperature The gas turbine is started in the normal start operating mode The gas turbine is partly started with upstream ven...

Page 43: ...he 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 can be freely connected to the terminals with the adequate lengths provided The connectors are defined for the following signal and supply voltages Table 3 2 Connector assignment for volt...

Page 44: ... 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 8 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 45: ...ached to the outside of the device A differential pressure technique continually determines the amount 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 13 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 14 Degr...

Page 46: ...een the phases in a star configuration 3 5 19 Machine side surge arresters option N56 The surge arrester limits voltage 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 ...

Page 47: ...pecific locking system is included in the converter 3 5 23 Customized duty cycle option Y45 The customer specific load cycle is included in the converter Description 3 5 Options SINAMICS GL150 6SL38503UM114PA0Z Operating Instructions Rev 201910301420 MUSTER 47 ...

Page 48: ...Description 3 5 Options SINAMICS GL150 6SL38503UM114PA0Z 48 Operating Instructions Rev 201910301420 MUSTER ...

Page 49: ...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 34 As well as adjusting the input voltage of the conve...

Page 50: ...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 51: ... 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 52: ...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 53: ...VZLWFKJHDU 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 6SL38503UM114PA0Z Operating Instructions Rev 201910301420 MUSTER 53 ...

Page 54: ...lass 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 influ...

Page 55: ...ndard 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 83 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 Req...

Page 56: ... 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 perfor...

Page 57: ...t 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 sus...

Page 58: ...ropriate 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 59: ...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 60: ...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 61: ...Figure 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 62: ...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 63: ...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 64: ...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 65: ...door interlocking 2 Insert a screwdriver into this opening 3 Turn the door handle until you feel resistance 4 Remove the screwdriver from the opening 5 Open the doors 4 5 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...

Page 66: ...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 67: ... 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 68: ...Preparations for use 4 6 Storage SINAMICS GL150 6SL38503UM114PA0Z 68 Operating Instructions Rev 201910301420 MUSTER ...

Page 69: ...ious 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 c...

Page 70: ... are specified in the associated sections Table 5 1 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 ...

Page 71: ...N EN 60999 1 VDE 609 1 5 4 Screwing the transport units together NOTICE Material damage caused by mechanical pressure on components Stress that occurs during transport may exert mechanical pressure on the components Material damage can result Line the cabinets up precisely with each other in order to avoid shearing forces when the base units are screwed together Install the converter only on a lev...

Page 72: ...r M12 screws are provided on each cabinet 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 Mo...

Page 73: ...the fan through the 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 6SL38503UM114PA0Z Operating Instructions Rev 201910301420 ...

Page 74: ...Mounting 5 7 Ensuring cooling air SINAMICS GL150 6SL38503UM114PA0Z 74 Operating Instructions Rev 201910301420 MUSTER ...

Page 75: ...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 76: ...onnect 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 damag...

Page 77: ...eration 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 6 3 Electromagnetic compatibility The following fundamental information and guidelines facilitat...

Page 78: ...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 79: ...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 80: ...g 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 81: ...WHG 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 82: ...hielding 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 s...

Page 83: ...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 84: ...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 85: ...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 86: ...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 137 6 13 3 Connecting circuit breakers To connect th...

Page 87: ...ure 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 ...

Page 88: ...cable 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 6SL38503UM114PA0Z 88 Operating Instructions Rev 201910301420 MUSTER ...

Page 89: ...ious 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 90: ...Commissioning SINAMICS GL150 6SL38503UM114PA0Z 90 Operating Instructions Rev 201910301420 MUSTER ...

Page 91: ... 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 92: ...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 93: ...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 94: ...peeds 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 generat...

Page 95: ...es 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 spee...

Page 96: ...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 97: ...d 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 ...

Page 98: ...Not 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 1...

Page 99: ...ange 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 missin...

Page 100: ...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 101: ... 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 102: ...onverter 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 6SL38503UM114PA0Z 102 Operating Instructions Rev 201910301420 MUSTER ...

Page 103: ... 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 capacitor...

Page 104: ... 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 105: ...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 106: ...uipped with a door interlocking system Depending on the design this is an electromechanical door interlocking system or optionally a safety locking system The power unit doors can only be opened under the following conditions The DC link current is zero The firing pulses are disabled Voltages at the input and output sides are below a minimum value The circuit breakers are open Maintenance 9 3 Open...

Page 107: ...he outside of the cabi net Operating company As required Visual inspection clean if required Clean the inside of the cabinet Siemens serv ice personnel Annually Visual inspection clean 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 thereafte...

Page 108: ...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 115 9 4 1 3 Checking hoisting solenoids and security bolts Check the hoisting solenoids a...

Page 109: ...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 115 9 4 1 7 Checking the filter mats Check the air filters in the cabinet doors for pollution Clean the filte...

Page 110: ...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 111: ...lose 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 in...

Page 112: ...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 113: ...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 114: ... 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 115: ...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 116: ... 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 117: ...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 118: ...he voltage or ground fault detection Changes to the voltage or ground fault detection e g to the measuring resistors are potentially lethal This can result in substantial property damage physical injuries and death Do not change the design of the voltage or the ground fault detection Removing the AVT combination module 1 Follow the five safety rules Page 15 2 Release the control cables Carefully e...

Page 119: ...Short circuit the snubber circuit capacitors before you withdraw the thyristor electronics Use the available threaded clamps 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 M10 7 Nm M12 10 Nm 9 7 3 Replacing the CompactFlash card To replace the CompactFlash card proceed as follows 1 ...

Page 120: ...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 121: ...f 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 122: ... not have core end markings mark the connecting point 4 Disconnect the 3 pole shielded cables for the measuring signal 5 Remove the green yellow ground wire connected to the insulated round rod 6 Remove the fixing screws from the insulated round rod and the transformer 7 Remove the current transformer from the cabinet See also The 5 safety rules Page 15 Installing the current transformer To instal...

Page 123: ...rs Defective snubber circuit capacitors may only be replaced on inserted thyristor electronics WARNING Electric shock hazard The snubber circuit capacitors are not equipped with discharge resistors The energy stored in the capacitors is discharged 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...

Page 124: ...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 125 to help you 3 Install the new thyristor electronics Tighten the screws with a tightening torqu...

Page 125: ...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 126: ... injury Serious material damage can also result Observe the five safety rules The thyristors are centered in the stack using their outer diameter and plastic bolts The plastic bolts are attached to the heat sinks A disk spring at the end of the stack provides the necessary pressure Maintenance 9 7 Repairs SINAMICS GL150 6SL38503UM114PA0Z 126 Operating Instructions Rev 201910301420 MUSTER ...

Page 127: ... Figure 9 8 Open ended wrench in the groove of the guide bolt 2 Insert the open ended wrench into the groove of the guide bolt Socket wrench Clamping screw Figure 9 9 Loosening the clamping screw with the socket wrench Maintenance 9 7 Repairs SINAMICS GL150 6SL38503UM114PA0Z Operating Instructions Rev 201910301420 MUSTER 127 ...

Page 128: ... the thyristor in the following sequence Push the thyristor from the front against the plastic bolt on the heat sink Make sure that the thyristor is correctly seated and centered Pay attention to the mounting position especially the polarity of the thyristor The adhesive symbols on the clamping pressure plates show the appropriate information Tighten the clamping screw with the socket wrench until...

Page 129: ...ic 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 ...

Page 130: ...he 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 SIN...

Page 131: ...er 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 ...

Page 132: ...Spare parts SINAMICS GL150 6SL38503UM114PA0Z 132 Operating Instructions Rev 201910301420 MUSTER ...

Page 133: ...d 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 ...

Page 134: ... PCBs Electronic components Disposal 11 2 Removing device components and old devices SINAMICS GL150 6SL38503UM114PA0Z 134 Operating Instructions Rev 201910301420 MUSTER ...

Page 135: ...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 136: ... 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 6SL38503UM114P...

Page 137: ... 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 138: ...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 139: ...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 140: ...Technical specifications and drawings B 2 Environmental conditions SINAMICS GL150 6SL38503UM114PA0Z 140 Operating Instructions Rev 201910301420 MUSTER ...

Page 141: ...lines 85 Converter bridge 36 Converter transformer 30 Current conduction permanent signals 36 Current transformer 33 35 Torque 122 D DC link reactor 30 32 dI dt reactor 44 Differential pressure switch 34 Direction of rotation changeover 93 Door interlock Cover screw 65 Electromechanical 106 Manual 65 Safety locking system 106 Door limit switch 34 DRIVE CLiQ 33 E Electromagnetic fields 18 Environme...

Page 142: ...tor 95 RC circuit 30 36 Rounding times 95 S Safety concept 28 Safety information Failure of a thyristor assembly 123 Fiber optic cables 129 Setpoint addition 93 Shock and tilt indicators Location 57 Purpose 56 Short circuiting 35 Siemens Industry Online Support App 136 Snubber circuit capacitor 119 Spare parts 135 Contact person 131 Spares On Web 131 Speed limitation 94 Storage Drive unit 66 Fan 6...

Page 143: ...V Vector control 95 Voltage Sensing Module VSM 40 Index SINAMICS GL150 6SL38503UM114PA0Z Operating Instructions Rev 201910301420 MUSTER 143 ...

Page 144: ...Index SINAMICS GL150 6SL38503UM114PA0Z 144 Operating Instructions Rev 201910301420 MUSTER ...

Page 145: ......

Page 146: ...0009938503 000030 01 EN 01 000993850300003001EN01 000993850300003001EN01 Further Information www siemens com LDA Siemens AG Large Drives Applications Vogelweiherstr 1 15 90441 NÜRNBERG GERMANY ...

Page 147: ...DA EN Tel 49 911 433 6422 Fax 49 911 433 6921 Email motoren doku aud internal siemens co m Our ref 0009938503000030 Date 30 10 2019 Documentation for 6SL38503UM114PA0Z 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 000993850300003001EN01 ...

Page 148: ......

Page 149: ...or binder 50 mm 120 g m2 SINAMICS GL150 6SL38503UM114PA0Z MUSTER Operating Instructions Spine label for binder 145 mm 120 g m2 SINAMICS GL150 6SL38503UM114PA0Z MUSTER Operating Instructions Installation Instructions ...

Page 150: ......

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