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Installation and Operating Instructions SINAMICS G180
Operating Instructions, 02/2019, 4BS0751-007

181

Maintenance

9

9.1

Maintenance and servicing

For your personal safety and in order to prevent material damage it is essential that you

follow the instructions given in section "Safety instructions" (Page 13), especially section

"Information about personal protection" (Page 16), and all safety-related instructions in your

product documentation. Pay particular attention to the safety notices on the product itself.
There is an appropriate maintenance schedule for each device type. We recommended that

maintenance is carried out at least once per year. For further information, please contact the

Service Center, see "Service & Support" (Page 189).
Retighten all screw connections at regular intervals.

Depending on utilization, the installed fans each have a service life of between 5 and 10

years.

The service life of the lithium battery on the board CB08 is 10 years.

The electrolyte capacitors are designed for a service life of 20 years.

●

Service the device after 5 years in accordance with a specified maintenance schedule.

●

Check and clean the equipment and air filter mats (if present) depending on the

accumulation of dust.

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Summary of Contents for SINAMICS G180

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Page 3: ..._______________ ___________________ SINAMICS Installation and Operating Instructions SINAMICS G180 Operating Instructions Translation of the original instructions 02 2019 4BS0751 007 Introduction 1 Safety information 2 Description 3 Preparations for use 4 Installation 5 Electrical connection 6 Commissioning 7 Operation 8 Maintenance 9 Spare parts 10 Diagnostics faults and warnings 11 Service Suppo...

Page 4: ... be operated only by personnel qualified for the specific task in accordance with the relevant documentation in particular its warning notices and safety instructions Qualified personnel are those who based on their training and experience are capable of identifying risks and avoiding potential hazards when working with these products systems Proper use of Siemens products Note the following WARNI...

Page 5: ...2 2 9 Security information 23 2 10 Components that can be destroyed by electrostatic discharge ESD 24 2 11 Electromagnetic fields 26 2 12 Radio telephones and mobile telephones 27 2 13 Note regarding fiber optic cables 28 2 14 Protecting fusing the external 230 V AC control voltage 28 2 15 Residual risks 29 3 Description 31 3 1 Updating inverter software or instructions 31 3 2 Order numbers Type d...

Page 6: ...T IO 57 3 3 14 3 Modbus RTU 60 3 3 14 4 Modbus TCP 63 3 3 15 Pre switch mode power supply 300 W 65 3 3 16 Water cooling 66 3 3 16 1 General information about water cooling 66 3 3 16 2 Direct water cooling diagram 67 3 3 16 3 Connecting water cooling 68 3 3 16 4 Venting the water cooling 68 3 3 16 5 Decommissioning and shutdown 69 3 3 16 6 Cooling water additives for the closed inverter cooling wit...

Page 7: ...3 6 7 2 Connecting the external 230 V AC control voltage 103 6 7 2 1 Protecting fusing the external 230 V AC control voltage 103 6 7 2 2 Switching over the hardware to an external 230 V AC control voltage 104 6 7 2 3 Preparations for accessing the switching power supply board 104 6 7 2 4 Connecting the external 230 V AC for compact devices 111 6 7 2 5 Control voltage 230 V AC for cabinet units 111...

Page 8: ... to NAMUR 1 139 8 3 3 Operation according to NAMUR 2 140 8 3 4 Operation according to NAMUR 3 141 8 3 5 Operation according to NAMUR 4 142 8 3 6 Operation according to NAMUR 5 143 8 3 7 Operation according to NAMUR 6 144 8 4 Controlling the external connections of the inverter 145 8 4 1 Function of the control cable terminals 145 8 4 2 Protective separation according to EN 61800 5 1 145 8 4 3 Sub ...

Page 9: ... thermistor inputs on peripheral board 173 8 8 2 NAMUR application 175 8 8 2 1 Control cable terminals for NAMUR application 175 8 8 2 2 Control cable terminals peripheral board 4 177 8 8 2 3 Mode setting of the NAMUR application 178 8 8 2 4 Assignment of the relay outputs 178 8 8 2 5 Assignment of the analog inputs 179 8 8 2 6 Assignment of the analog outputs 179 8 8 2 7 Input Mandatory mains pow...

Page 10: ...hnical data for operation 200 C 6 Tightening torques for power cables 201 C 7 Technical data of the control cable terminals 201 C 8 Technical data and identification of the PTC thermistor input at peripheral boards 2 and 4 203 C 9 Technical data of the direct water cooling 204 C 10 Permissible substance values for the cooling water 205 C 11 Threshold values for fan control system 206 C 12 Derating...

Page 11: ...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 1 2 Validity This document is applicable for SINAMICS G180 T7 not capable of energy recovery Order number 6SE01 from software version 11C0242 CF78 1 3 Text format features Text format feat...

Page 12: ...rating Instructions 02 2019 4BS0751 007 1 4 Presentation of the display buttons in the operating instructions Table 1 1 Presentation of the display buttons in the text Button on the inverter display Presentation in the text On Off P S I ENTER up arrow down arrow 1 5 Specific features The following text formats are used in this operating manual ...

Page 13: ... Press the button on the control panel twice S I Press both buttons simultaneously Display text P SYSTEM DATA Text shown in the control panel display is presented like this If you have to branch in a menu the text will be shown as follows P MACHINE POWER CONV P speed default t accel P MACHINE POWER CONV symbolizes the main menu P speed default the submenu and t accel the parameter In this case you...

Page 14: ...Introduction 1 5 Specific features Installation and Operating Instructions SINAMICS G180 12 Operating Instructions 02 2019 4BS0751 007 ...

Page 15: ...ts for example anti condensation heating Wait until the capacitors have discharged 2 Lockout to protect against reconnection 3 Make sure that the equipment is de energized and in a no voltage condition 4 Ground and short circuit 5 Cover or enclose adjacent components that are still live When you have finished working on the equipment apply the measures in reverse order DANGER High voltages Potenti...

Page 16: ...ied and Siemens approved components Observe the following instructions if you would like to integrate your own components in the system WARNING Components which are not approved It is dangerous to use components which are not tested not certified and not approved by Siemens This can result in death serious injury or material damage Use only components which are tested certified and approved by Sie...

Page 17: ...hat the converter is volt age free immediately Danger due to hazardous voltages when the cabinet doors are open These voltages can remain due to self excitation if the connection to the motor is not removed Some surfaces in the inverter are hot during operation and for some time afterwards Fans in the inverter can continue to rotate after the unit has been switched off After disconnection of the l...

Page 18: ...he EMERGENCY OFF button is actuated WARNING Automatic startup Depending on parameter settings and connection of external control devices the inverter can start up automatically when the line voltage is connected This can result in death serious injury or material damage Confirm whether or not your system is capable of automatic starting and if appropriate take measures to ensure personal safety an...

Page 19: ...work is only carried out by qualified personnel under due observance of the five safety rules the information in these operating instructions and the instructions on the product itself DANGER Auxiliary and external supply systems Hazardous voltages e g control voltage signal voltage supply voltage for heaters and fans can persist even after the inverter has been switched off Contact with live part...

Page 20: ... that no accessible parts of the equipment are energized or connected in any way to a dangerous voltage source Use an earthing spider for grounding purposes Read the information provided in the section Safety instructions regarding maintenance and repairs in Maintenance and servicing in your operating instructions Wear personnel protective gear such as goggles ear protection and helmet to protect ...

Page 21: ...ropriate precautions before touching any components 2 5 Notes on liquid cooling Follow the safety instructions for liquid cooled converters WARNING Electric shock as a result of defective cooling liquid system Short circuits can develop in electrical installations when liquid escapes from cooling circuits This can result in death serious injury or material damage Note the technical data of the liq...

Page 22: ... NOTICE Leaking antifreeze has a corrosive effect and may cause short circuits When a connection is disconnected in the cooling circuit antifreeze can escape and drip down onto lower areas These areas can corrode and therefore cause short circuits Whenever you disconnect a connection in the cooling circuit cover lower areas Thoroughly remove antifreeze from areas that it has come into contact with...

Page 23: ...oper use of inverters Inverters are components which are intended for installation in electrical systems or machines Commissioning of the inverters is prohibited until one of the following two conditions is verifiably fulfilled The machine complies with the requirements of the following directives Machinery directive 2006 42 EG EMC directive 2014 30 EG The electrical installation complies with the...

Page 24: ...properly trained personnel have access Procedure You are responsible for the safety of the system You must ensure that the following requirements are fulfilled Basic planning and all the work involved in transporting assembling installing commissioning maintaining and repairing the equipment is only carried out by qualified personnel or personnel supervised by responsible skilled technicians The o...

Page 25: ...ustrial security concept Siemens products and solutions constitute one element of such a concept Customers are responsible for preventing unauthorized access to their plants systems machines and networks Such systems machines and components should only be connected to an enterprise network or the internet if and to the extent such a connection is necessary and only when appropriate security measur...

Page 26: ... concept Protect files stored on exchangeable storage media from malicious software by with suitable protection measures e g virus scanners WARNING Malfunctions of the machine as a result of incorrect or changed parameter settings As a result of incorrect or changed parameterization machines can malfunction which in turn can lead to injuries or death Protect the parameterization parameter assignme...

Page 27: ...lating table supports or clothing made of synthetic fibers Bring components into contact only with ESD compliant materials e g ESD tables ESD surfaces ESD packaging Only carry out measurements on the components if one of the following conditions is met The measuring device is grounded with a protective conductor for example The measuring head of a floating measuring device has been discharged dire...

Page 28: ... a person s health or even death It is therefore forbidden for persons with heart pacemakers to enter these areas The plant operator is responsible for taking appropriate measures labels and hazard warnings to adequately protect operating personnel and others against any possible risk Observe the relevant nationally applicable health and safety regulations In Germany electromagnetic fields are sub...

Page 29: ... injuries to personnel Missing pulses during inverter operation can occur Defects of the power elements can occur The inverter can shut down Contactors can chatter Interference on binary outputs Do not use radio telephones 2 W in close proximity to the device Radio telephones with lower outputs must not be used at a distance of less than 1 m from the inverter CAUTION Mobile telephones The use of m...

Page 30: ...verters with fiber optic cable systems using a camera flash light when they are in operation Only photograph these types of inverters when they are in a no voltage state 2 14 Protecting fusing the external 230 V AC control voltage WARNING External control voltage without fuse protection If you use an external control voltage without suitable protection e g fuses then overloads and short circuits c...

Page 31: ...conductive contamination Parameterization programming cabling and installation errors Use of radio devices cellular phones in the immediate vicinity of the controller External influences damage 2 High temperatures and emissions A fault can occur as a result of the following for example Component malfunctions Software errors Operating and or environmental conditions outside of the specification Ext...

Page 32: ...can result from the pressure that can possibly build up inside 7 Dangerous electric arcs during internal faults The drives are designed according to the relevant IEC standards and have been tested in line with strict type testing procedures They were developed and manufactured so that there is a very low probability of internal faults occurring However internal faults cannot be completely ruled ou...

Page 33: ...VERTER DATA Version 2 If the inverter software version is higher than the version of the operating manual download the current version of the manual from this website http www siemens com 3 If the inverter software is no longer current then update the inverter software by using the software IMS Contact the Service Center of Siemens in Ruhstorf Page 190 for more detailed information 3 2 Order numbe...

Page 34: ...ower system 0 Not relevant for cabinet 1 6 pulse input 2 12 pulse input 3 18 pulse input 4 24 pulse input A 9th position Number of systems connected in parallel A Compact unit B Single device with system management C Multiple device with 2 parallel circuits D Multiple device with 3 parallel circuits E Multiple device with 4 parallel circuits F Not relevant for cabinet G Multiple device with 5 para...

Page 35: ...git 8 13 Digit 2 means Output current approx 10 82 820 A In the case of cabinets con taining multiple compact units the output current of the largest compact unit must be specified It is not permissible to state the digit 9 here If the rated current of a converter is 940 A for example the order number positions for the output current must be reduced 11th Digit 3 12 Digit 8 13 Digit 8 This can mean...

Page 36: ...f the connected motor 400 Rated supply voltage V 12 6 Pulse operation Input Output If this information is missing then it is a 6 6 pulse converter Type code e g 2T 2 A 0 7 4 0 0 055 The type code describes the converter type in more detail Always state the type code as well as the serial number and other rating plate data for enquiries to the factory What the icons mean Example Designation Option ...

Page 37: ...ent units 0 Number of parallel machine converter systems 0 Single device without system management 1 Single device with system management 2 7 Multiple device with corresponding number of parallel systems and system management units 055 Achievable shaft output kW for continuous output current If the first position is 9 the other two digits show the power in kW 100 Other version designation e g A ty...

Page 38: ...r and with LHF M Without RFI suppression filter and with LHF D Converter output filter D Standard du dt filter V Strengthened du dt filter S Sine wave filter I Internal converter display O Without internal converter display B With internal and external converter display E With external converter display I With internal converter display R With internal Russian converter display S With external Rus...

Page 39: ...your own components in the system WARNING Components which are not approved It is dangerous to use components which are not tested not certified and not approved by Siemens This can result in death serious injury or material damage Use only components which are tested certified and approved by Siemens 3 3 2 Peripheral boards 1 to 4 A95 option G02 to G05 3 3 2 1 General information about the periph...

Page 40: ...ard 1 Peripheral board 2 Peripheral board 3 Peripheral board 4 2 PTC thermistor inputs one ATEX certified one warning motor temperature monitoring for motors in the Ex zone X X A Safe torque off digital input according to EN ISO 13849 1 2008 Cat 3 X X 9 digital inputs DI X X 3 relay outputs DO X X 2 analog outputs AO X X X X Power supply unit 24 V 300 mA X X Peripheral boards 2 and 4 are in additi...

Page 41: ...afe functioning of equipment with respect to explosion risks DIN EN 60947 8 2013 Low voltage switchgear and controlgear Part 8 Tripping units for integrated thermal protection PTC for rotating electrical machines IEC 61508 1 2010 Functional safety of electrical electronic programmable electronic safety related systems Part 1 General requirements IEC 61508 2 2010 Functional safety of electrical ele...

Page 42: ...nd an ATEX motor temperature monitoring must always be replaced using certified original parts Only replace parts after prior consultation with the factory Use the Safe torque off function of the inverter for induction and synchronous motors If two additional faults occur in the power section for synchronous motors this can result in residual rotation The residual rotation angle can be maximum 180...

Page 43: ... inverter control processes the peripheral board signal In the case of an excessively high motor temperature or for the Safe torque off function the inverter inhibits the IGBT firing signals The supply voltage for the driver stages is additionally switched off These two switch off paths ensure that the power infeed to the motor is immediately interrupted This rules out any additional motor tempera...

Page 44: ...stor instead of the PTC thermistor to the control cable terminals 3 3 2 3 Safe torque off with single circuit trip The control cable terminals X2 19 X2 20 provide a safety oriented input for safe torque off to EN ISO 13849 1 2008 category three This input safely prevents starting the machine Use this input for example for safe shutdown in the case of servicing work on the machine When using the in...

Page 45: ...ter is configured for a two circuit trip 3 3 2 5 Switchover single circuit two circuit tripping The safety related Safe torque off function in the inverter is purely based on a hardware related shutdown of the power section The corresponding input circuits only act on the two shutdown paths in the inverter via the hardware circuit NOTICE Bail switch S3 Just bail switch S3 on peripheral board DI DO...

Page 46: ... 19 20 Bail switch S3 closed two circuit trip additionally via X2 24 3 Figure 3 2 Position of the bail switch S3 on peripheral board DI DO Parameter P INVERTER DATA STO Using this parameter you tell the inverter software as to whether you are using the Safe torque off function with single circuit or two circuit trip The parameter is not relevant for the actual safety related shutdown via the two s...

Page 47: ...ue temporarily in the 4th status line or in the IMS if you are connected with a PC 5 If required enter the necessary switch on commands so that the inverter is at least in the ready state i e is in the Status Rdy f work The READY LED is lit 6 Simultaneously open the safety circuit s that is are connected as follows For single circuit trip at X2 19 20 For a two circuit trip additionally at X2 24 3 ...

Page 48: ...splay changes to Inverter fault Test safe torque off In this case it is crucial that you contact the factory Additional test if you use a single circuit trip 11 Open terminal input X2 24 if a signal is connected The inverter either does not display a response or it may only display a response that is parameterized for input X2 24 independent of the Safe torque off function It is not permissible th...

Page 49: ...rcuit trip and the parameter to two circuit trip X2 20 24 14 The inverter changes into the Switch interlock state LED READY goes dark The Safety torque off active message is displayed at the converter You have either only set the parameter or simultaneously also switch S3 to the single circuit trip For all additional deviations when checking the Safe torque off function it is crucial that you cont...

Page 50: ...ox 100 Ω 2 Ensure that 24 V is applied at control cable terminal X2 8 When required jumper X2 8 and X2 3 3 Connect power to the inverter so that the READY LED on the display lights up 4 Increase the resistance at the potentiometer The converter must go to FAULT at the latest for 3 8 kΩ LED READY goes dark The red FAULT LED is lit The inverter displays fault message Fault PTC thermistor X3 90 91 5 ...

Page 51: ...e If the clearance between the resistors and the neighboring components is selected too small fire can occur due to overheating This can result in death serious injury or material damage Maintain a minimum clearance of 200 mm 3 3 3 1 Dimensioning the brake resistor Select a resistance value of at least that stated in the technical data This value corresponds to the minimum configurable value The m...

Page 52: ...The connection box can be provided on the left or the right side If you require several resistors for series or parallel connection install the resistors next to each other This also applies for wall mounting 3 3 4 Parameter overview A more detailed overview of all parameters can be found in the IMS software or in the parameterization guide You can find both on the Internet http www siemens com 3 ...

Page 53: ...for all compact and compact Plus devices The cover is 5 mm wider on both sides than the inverter Take account of this clearance for the alignment Leave the outlet area at the front clear Proceed as follows to install the roof supplied loose 1 Screw the inverter without cover on to a mounting plate Do not tighten the top two mounting screws completely 2 Slide the cover under the not yet completely ...

Page 54: ...G K6 In this case option Q W is only possible in a cabinet system 2X BG K6 BG S1 BG S3 No different dimensions than standard device CAUTION Serious injury and material damage caused by arcs If the mains power supply cable is not properly connected to the main switch for the Q W option destruction due to arcs can occur Connect the mains power supply line to the main switch properly Follow the conne...

Page 55: ...t be the same type Connect both inverters to the mains power using a common supply line Operate the mains power feed in current of each inverter at maximum 75 of the rated current The mains power supply connection cables from K1 2 4 6 to both inverters must be the same length and have the same cross section You can use a normal cable to connect the DC link e g H07VK in the cabinet or NYY outside t...

Page 56: ...this case configure the inverter with brake resistor to On NOTICE Destruction of the inverters If you use one of the following configurations without consulting the factory the inverter can be destroyed Two different inverters More than two inverters More than 75 mains power feed Only one mains power connection DC network for cabinet units Check the design with DC network exactly Consult the facto...

Page 57: ...sioning maximum motor cable length Page 100 3 3 12 Sine wave filter Note the following information for the operation of a sine wave filter A sine wave filter is available as an option for the motor power supply It must be noted that sine wave filters are only designed for the nominal clock frequency Therefore the parameter f pulse min under P INVERTER DATA must always be set to the nominal clock f...

Page 58: ...onnection Switch for terminating resistor PROFIBUS address settable LED bus diagnostics LED Offline Unused LED LED Online Figure 3 5 PROFIBUS board Table 3 4 PROFIBUS board external elements component Function LED Status only just visible under the grey cover Flashing red at different frequencies Hardware fault on the PROFIBUS board con tact Customer Service Flashing green at 1 Hz 0 5 s on 0 5 s o...

Page 59: ... in the length of the PROFIBUS telegram Flashing at 4 Hz 0 12 s On 0 12 s Off Error when initializing PROFIBUS Off No bus fault 3 3 14 2 PROFINET IO You can purchase a PROFINET board as accessory it can also be retrofitted This is installed under the grey plastic cover It is available in two versions with Ethernet or alternatively with fiber optic sockets Based on the designation on the rating pla...

Page 60: ... Module status display L A S Link Activity Speed display Port 1 L A S Link Activity Speed display Port 2 Figure 3 6 PROFINET board Version with Ethernet sockets PROFINET board with FO connection SCRJ connector option code F SCRJ fiber optic socket Port 1 SCRJ fiber optic socket Port 2 NS Network status display MS Module status display L A S Link Activity Speed display Port 1 L A S Link Activity Sp...

Page 61: ... Fatal event Fatal internal error This display occurs in conjunction with a red Module status LED Flashing red 1 Hz Error station name A station name has not been assigned factory setting Flashing red 2 Hz Error IP address An IP address has not been assigned factory setting Flashing red 3 Hz Error configura tion The reference configuration expected identification differs from the actual configurat...

Page 62: ... communication Yellow flickering Activity with 10 Mbit Ethernet connection established and active communication 3 3 14 3 Modbus RTU You can purchase a Modbus board as an accessory The Modbus board is installed under the plastic cover The board can be retrofitted You recognize from the description Type code _ _ _ _ M _ on the rating plate that a Modbus board has been integrated Modbus connection Sw...

Page 63: ...s Switch for terminating resistor A bus line must be terminated with a terminating resistor A terminating resistor can be fitted in the connector Select the switch position accordingly Switch up resistor On Available Modbus ad dresses You can set the Modbus address using the software as follows Under P INTERFACES P fieldbus P PB PN Modbus P Modbus RTU BUS address a value 0 247 can be set The addre...

Page 64: ...is switch according to the interface you want to use 0 RS 485 1 RS 232 LED Status above the DIL switches only visible if the blue cover is removed Flashing red at different frequencies Hardware error on the Modbus board Contact the service de partment Flashing green at 1 Hz 0 5 s On 0 5 s Off Initialization of the Modbus board OK Flashing green at 2 Hz 0 25 s On 0 25 s Off Initialization of the Mo...

Page 65: ...an accessory The Modbus board is installed under the plastic cover The board can be retrofitted You recognize from the description Type code _ _ _ _ T _ on the rating plate that a Modbus TCP board has been integrated Figure 3 9 Modbus TCP board 1 Internal bus connection 2 Ethernet connection socket RJ45 3 Configuration switch 4 Anybus Watchdog 5 Status LEDs Figure 3 10 Modbus TCP board ...

Page 66: ...using the software as follows IP address under P INTERFACES P fieldbus P PB PN Modbus P Modbus TCP IP sub net under P INTERFACES P fieldbus P PB PN Modbus P Modbus TCP SN gateway under P INTERFACES P fieldbus P PB PN Modbus P Modbus TCP GW If you enter a value of 0 0 0 0 for the IP address then the following standard values are used the IP address is then completed by the hardware IP address 192 1...

Page 67: ...r supply 300W L0329237 main PC board with small mounted PC board L0329239 Inputs Rated input voltage UD UD 250 1300 V DC switched on above 150 V switched off 100 V and 1500 V External supply X1 230 V AC is switched on if 300 V DC 250 V switched off for 270 V Control voltage fan X32 Controlling the fan voltage X11 with 0 V 15 V 24 V 10 15 19 V 12 V 20 24 30 V 24 V Outputs SNT 300 V X4 fan 24 V 300 ...

Page 68: ...urchased with water cooling From the type designation 2T 7 you can identify that a unit is equipped with water cooling Water cooling is adapted to the existing conditions Further information can be found in the order related documentation The Water cooling section describes the design of the direct water cooling with open cooling circuit Recooling of the coolant is not performed Provide correspond...

Page 69: ...ooling diagram Structure A Components in the inverter cabinet B Components provided by the customer Ventilation Air water heat exchanger with fan for interior Electromagnetic valve NC Electromagnetic valve NO Stop valve regulation of the flow rate Flow rate regulation valve Filter Bypass The version is optional Figure 3 13 Diagram Direct water cooling ...

Page 70: ... line vent the water cooling Also vent the water cooling if it is operated in an enclosed system 1 Disconnect the inverter before the cooling from the power supply and secure it against being switched on again 2 Open the solenoid valve H1 K2 Y1 to vent the water cooler Proceed as follows Open the isolating blade terminals H1 K1 X5 or X4 12 and 13 At terminals H1 K1 X5 or X4 11 and 14 connect an au...

Page 71: ...g valve is closed until no more water exits The water cooling system is drained before the inverters are shipped by the manufacturer 3 3 16 6 Cooling water additives for the closed inverter cooling with cooling unit optional Use a cooling water additive for the closed cooling system of the inverter Siemens recommends the agent Antifrogen N made by Clariant as a cooling water additive The concentra...

Page 72: ...Description 3 3 Accessories Installation and Operating Instructions SINAMICS G180 70 Operating Instructions 02 2019 4BS0751 007 ...

Page 73: ...sting gear This can result in death serious injury or material damage Never stand in the area beneath a suspended load WARNING Accidents during transport and when lifting This can result in death serious injury or material damage Carefully observe the transport instructions in this document as well as the generally valid accident prevention regulations especially BGI 556 Always wear personnel prot...

Page 74: ...nditions package the devices in accordance with the special requirements Consult the factory for this for example for marine packaging Never lift the compact devices at the plastic cover but always from below according to the following diagrams Lifting compact devices wrong Lifting compact devices correct NOTICE Damage to converters during transportation When returning the unit only transport it i...

Page 75: ...Preparations for use 4 1 Transporting inverter Installation and Operating Instructions SINAMICS G180 Operating Instructions 02 2019 4BS0751 007 73 Figure 4 1 Lifting with a crane ...

Page 76: ...erters Only store the equipment in a dry storage area with undamaged packaging Observe the information in Chapter Technical data for storage Page 194 NOTICE Destruction of the converters as a result of improper storage Observe the environmental conditions for storage stated in the technical specifications The converters will be destroyed if you store them outdoors Store the converters in enclosed ...

Page 77: ... Use a low inductance and wide area shield at the cable entry for EMC reasons Use a plait on the PE rail as a protective measure For signal lines with Sub D male or female connector place the shield over the Sub D connector or socket Where relevant also connect the shield at the cable entry Install cables in such a way that there are no crossovers between control cables and power cables If you can...

Page 78: ...heet The sheet simultaneously provides shielding for the incoming and outgoing motor wires 4 3 2 Examples for correct EMC connection You can see below some examples of expert connection of shielded cables at compact units If you would also like to apply cable shields with metal cable ties or metal clamps install shielding buses for cabinet devices Cable entry on a compact device with shield connec...

Page 79: ...tions for use 4 3 EMC Installation and Operating Instructions SINAMICS G180 Operating Instructions 02 2019 4BS0751 007 77 Signal cable Control cable Motor and power supply cable Figure 4 3 EMC wiring overview ...

Page 80: ...ed Contact clip Shielding bus Figure 4 4 Shield connection for cabinet devices Figure 4 5 Shield connection for cable type NYCWY 4 3 3 Radio interference class You can read the radio interference class of the inverter at the version designation of the rating rate or from the order confirmation Further information can be found in the Type designations Page 31 section ...

Page 81: ...its Grounded line supply IT line supply or I 400 A Optional Compact units Cabinet units All units Category C1 Product with a rated voltage of 1000 V use in the 1st environment Category C2 Product with a rated voltage of 1000 V use in the 1st environment and in stallation and commissioning by personnel knowledgeable about EMC Category C3 Product with a rated voltage of 1000 V use in the 2nd environ...

Page 82: ...er in safe non hazardous areas Motor in the Ex Zone Motors connected to the converter can be operated in the hazardous zone Also observe the following conditions Ensure that the motor is approved for converter operation and that it has a corresponding rating plate for converter operation Ensure that the motor is approved for the Ex Zone Also check the motor rating plate Ensure that the motors are ...

Page 83: ...ed information can be found in the section Peripheral boards 1 to 4 Page 37 The converter is electronically shutdown Safety during shutdown The risk analysis according to EN 1050 or DIN EN ISO 14121 draft standard showed that in comparison to the shutdown using contactors only the additional hazard due to dangerous shock currents occurred in the converter Due to the redundant design of the electro...

Page 84: ...Preparations for use 4 4 Realizing operation in the explosion protected zone Installation and Operating Instructions SINAMICS G180 82 Operating Instructions 02 2019 4BS0751 007 ...

Page 85: ...tion IP55 NEMA1 Higher NEMA types on request Open Type The compact devices are designed in accordance with degree of protection IP20 acc to EN 60529 and as open type devices acc to UL 50 This ensures protection against electric shocks To ensure protection against mechanical stress and climatic conditions too the components should only be operated in housing cabinets rooms that fulfill the requirem...

Page 86: ...for the equalization We recommend the following procedure when mounting the compact unit to walls or panels 1 Prepare the holes for the four fixing screws Refer to the technical data for the relevant dimensions 2 Screw in the two lower screws until they have taken a firm grip 3 Lift the compact unit if required using suitable lifting equipment onto the two lower screws The hole in the upper center...

Page 87: ...ilable as an accessory for all compact and compact Plus devices The cover is 5 mm wider on both sides than the inverter Take account of this clearance for the alignment Leave the outlet area at the front clear Proceed as follows to install the roof supplied loose 1 Screw the inverter without cover on to a mounting plate Do not tighten the top two mounting screws completely 2 Slide the cover under ...

Page 88: ... been separated for transport make all the connections at the separation points again NOTICE Overheating If you do not remove the transport rails installed on the cover before commissioning the inverter can be damaged due to overheating Remove the transport rails before commissioning Canopy Install the protective covers on the top of the cabinet Proceed as follows 1 Remove any transport rails pres...

Page 89: ... 4 Installing cabinet units Installation and Operating Instructions SINAMICS G180 Operating Instructions 02 2019 4BS0751 007 87 Protective cover Screws Bolts supplied in the switch cabinet Figure 5 2 Protective cover ...

Page 90: ... At the 9 pin D sub connector X51 and with a supplementary 24 V voltage supply for a maximum cable length of 1000 m Procedure Use the display in control panels or doors Note the following dimensions for the opening Width x Height mm 138 1 92 0 8 The degree of protection is IP54 Contrast setting Figure 5 3 Dimension drawing External display Connection for installation in the switch cabinet door wit...

Page 91: ...structions SINAMICS G180 Operating Instructions 02 2019 4BS0751 007 89 Figure 5 4 Display Installation in switch cabinet door Connection for external installation with maximum 1 000 meters connection cable length Figure 5 5 Display external installation Use shielded connection cables ...

Page 92: ...Installation 5 5 Mounting an external display option Installation and Operating Instructions SINAMICS G180 90 Operating Instructions 02 2019 4BS0751 007 ...

Page 93: ...le ducts Make sure that the cables are mechanically secured e g using cable ties against accidental disconnection For detailed information about cabling and connections please refer to EN 61800 5 1 Chapter 4 3 8 Note Familiarize yourself with the local safety requirements and national safety guidelines and always observe them NOTICE Use of aluminum cables at unsuitable terminals If you connect alu...

Page 94: ...of a short circuit must be less than 8 ms Procedure when the motor has a significantly lower rating than the inverter Imot 0 5 Ifu Protect the inverter against short circuits Dimension the fuse value as follows Ifuse 2 Imot Use the next lower standard fuse value than calculated Parameterize the inverter parameter P INVERTER DATA I contin as a maximum to the fuse value Locate a general line fuse or...

Page 95: ...1 6 5 Line supply connection 6 5 1 Suitable supply line configurations The converters are suitable for the following line supply types Table 6 1 SINAMICS G180 T7 and appropriate line supply types Line voltage Type designation Line system type 400 V 2T 40 TT or TN line system grounded 500 V 2T 50 TT TN or IT line system grounded or not grounded 690 V 2T 60 TT TN or IT line system grounded or not gr...

Page 96: ...the motor in order to avoid injuries due to indirect contact Protective earth conductor Due to the high leakage currents of the unit 3 5 mA one or more of the following conditions must be fulfilled for fixed connection of the protective earth conductor The protective earth conductor must have a cross section of at least 10 mm2 Cu or 16 mm2 Al Automatic tripping of the power supply in the event of ...

Page 97: ...verter You do not need any N conductor Procedure Only connect the inverter via a permanently routed connecting cable Refer to the following table for the possible connection cross sections for compact devices The connection cross sections for cabinet units can be found in the technical data of the inverter documentation Observe the switch manufacturer instructions when connecting cables directly a...

Page 98: ...rs with higher pulsed inputs are available for higher outputs from approx 500 kW as they cause smaller circuit feedback on the mains power supply Connect the inverter to the mains power supply depending on the pulse operation Table 6 4 Line supply connection dependent on the pulse operation Pulse op eration Can be recog nized in the type code Connection at the inverter at X1 U1 V1 W1 6 2T A Three ...

Page 99: ...ine voltage on the device No adjustment is necessary for compact units with a width of 165 mm or 225 mm In the case of compact units with a width of 350 mm or 500 mm you reconnect the jumpers according to the following table Table 6 5 Necessary jumpers for setting the line voltage Rated voltage V Voltage tolerance V Necessary jumpers 230 184 265 1 2 4 8 400 320 460 1 6 7 8 460 368 529 1 5 7 8 500 ...

Page 100: ... 6 6 Motor connection 6 6 1 Motor selection Three phase asynchronous motors or three phase synchronous motors can be used for your inverter The use of several motors simultaneously is permitted The total of the motor outputs must not exceed the inverter output You may operate smaller and larger motors in parallel on one inverter Take into account during the motor dimensioning that additional losse...

Page 101: ...do not occur Motors which are dimensioned for inverter operation therefore do not cause any problems If you would like to connect older motors or motors which are not suitable for inverter operation please consult the motor manufacturer Pay attention to the exact compliance with the peak voltage in the motor for explosion protected motors 6 6 3 Motor voltage and type of circuit Operate the motor a...

Page 102: ...age currents This can cause the cable to overheat This can result in death serious injury or material damage Use a shield cross section that is as a minimum half the line conductor cross section For a thinner shield or for a shield manufactured out of steel braiding route a PE conductor which as a minimum is half of the line conductor cross section in parallel with the motor cable 6 6 5 Dimensioni...

Page 103: ...00 m 300 m 300 m Cabinet units 690 V 2T 7 8 5 6 60 100 m 140 m 250 m 300 m Cabinet units 690 V 2R 876 150 m 200 m 300 m 350 m The data in the table specifies the typical cable length in the sense of the distance between the motor and the converter when parameterizing the standard clock cycle frequency Larger distances are also possible for individual types Contact the factory for precise values if...

Page 104: ...ion with the manufacturer 6 6 6 Connecting motor cable Connect the motor to terminals U2 V2 W2 of terminal strip X1 of the inverter Refer to the technical data for the correct tightening torques for the power cable connection 6 6 7 Connecting the PTC thermistor of the motor to the inverter Connect the PTC thermistor of non explosion protected motors without peripheral board 2 4 to terminals 27 28 ...

Page 105: ...ntary mains power failures The initialization time of approx 3 s does not apply in the case of external supply 6 7 2 Connecting the external 230 V AC control voltage 6 7 2 1 Protecting fusing the external 230 V AC control voltage WARNING External control voltage without fuse protection If you use an external control voltage without suitable protection e g fuses then overloads and short circuits ca...

Page 106: ...ternal control voltage Switching power supply with connector on external control voltage 6 7 2 3 Preparations for accessing the switching power supply board Preparing compact devices with size up to 165 mm This instruction is applicable for compact devices up to a size of 165 mm with the identifier 2T 07400 011 or 2T 07500 015 Procedure 1 Unscrew the blue cover at the screw above X25 and lift up t...

Page 107: ...ifier 2T 07400 015 or 2T 07500 037 Procedure 1 Turn the four fixing screws of the gray cover through 90 and lift up the cover 2 Unscrew the blue cover at the screw above X25 and lift up the cover 3 Turn the four fixing screws of the swivel section by 90 swivel the swivel section to the right and clip the swivel section to the side panel according to the picture below 4 Replug the connector 5 Reass...

Page 108: ...ove X25 and lift up the cover 3 Remove the cover above the motor connection terminals 4 Remove the fan power supply board with the five fine wire fuses Undo the four screws and unplug the cable for this 5 The switched mode power supply board is located below with a white connector and the sockets X2 for internal and X5 for external 6 Insert the connector into external 7 Reassemble in the inverse o...

Page 109: ...nection terminals 4 On the fan supply board with the five miniature fuses change over the connector from socket X100 to X200 5 Reassemble in the inverse order Note Occurrence of malfunctions Malfunctions can occur if you change over the connection of sockets X2 5 for external internal on the switched mode power supply board Leave this connection on external Providing compact devices with frame siz...

Page 110: ... opened control electronics 4 Remove the fan power supply board with the five fine wire fuses Undo the four screws and unplug the cable for this 5 The switched mode power supply board is located below with a white connector and the sockets X2 for internal and X5 for external 6 Insert the connector into external 7 Reassemble in the inverse order Note Occurrence of malfunctions Malfunctions can occu...

Page 111: ...r if you change over the connection of sockets X2 5 for external internal on the switched mode power supply board Leave this connection on external Preparing compact devices with frame size K6 with 400 V or 500 V This instruction applies to compact units with the frame size K6 with L W 1125 500 mm and 400 V or 500 V rated voltage Procedure 1 Turn the four fixing screws of the gray cover through 90...

Page 112: ...r at the screw above X25 and lift up the cover 3 Turn the four fixing screws of the swivel section by 90 swivel the swivel section to the right and clip the swivel section to the side panel 4 The fan power supply board with five fine wire fuses and the switching power supply board are underneath 5 On the fan supply board change over the connector from socket X100 for internal to X200 for external ...

Page 113: ...n values for external control voltage Maximum cross section 2 5 mm Fuse protection Miniature fuse in accordance with EN 60127 2 A 6 A slow maxi mum 150 VA Miniature circuit breaker 2 A 6 A characteristic D maximum 150 VA Voltage 230 V 15 20 Frequency 47 Hz 63 Hz For compact units with frame size K4 terminals 101 and 102 are located on a board under the plastic cover above the motor terminals 6 7 2...

Page 114: ...an result The device may only be operated with a protected external control voltage Note the following recommendation Install one of the following options to protect the external control voltage Miniature fuse in accordance with EN 60127 6 A slow acting maximum 100 VA Miniature circuit breaker 6 A characteristic D maximum 100 VA 6 7 3 2 Switching over the hardware to an external 24 V DC control vo...

Page 115: ...nstructions 02 2019 4BS0751 007 113 Figure 6 5 Connection for external control voltage Use the following connection values Maximum cross section 2 5 mm Protection Miniature fuse in accordance with EN 60127 6 A slow acting maximum 100 VA Miniature circuit breaker 6 A characteristic D maximum 100 VA Voltage 24 V DC 15 ...

Page 116: ...Electrical connection 6 7 External control voltage Installation and Operating Instructions SINAMICS G180 114 Operating Instructions 02 2019 4BS0751 007 ...

Page 117: ...ply and without motor WARNING Injury due to explosion of capacitors If the unit has been stored for longer than two years the DC link capacitors can explode during commissioning Reform the DC link capacitors if the unit has been stored for longer than two years Contact the factory to determine what measures must be taken Checking the connections 1 Check all connections at the converter Check wheth...

Page 118: ...er 2T 8 also reconnect the fan transformer T4 to the rated mains voltage and check whether the transformer is connected to the correct voltage Compact units identifier 2T 0 supply the fans via the DC link Thus there is no configuration work for you Table 7 1 Voltage range of the different device types Device Type designation according to rating plate Supply voltage range 400 V compact unit 2T 0 40...

Page 119: ... main switch 7 Perform the test with maximum DC 500 V for a maximum of 2 minutes between the U1 V1 W1 U2 V2 W2 jumper and the enclosure 8 After completion of the test connect the output voltages U V W with PE 9 Undo the above actions 7 2 Checks with mains power supply and without motor The load dependent actual values e g I motor T motor or P motor are also displayed without motor They are 0 in th...

Page 120: ...et as the default at the factory For additional information refer to the section titled Standard application Page 168 If you would like to make other changes to the parameters these changes can be made at this point In this case the parameter P DRIVE DATA A Standard changes to P DRIVE DATA A specific Note Loss of all configured values If you select other applications before the changed parameters ...

Page 121: ...ution which the tacho should have Use at least 1 024 pulses 360 If you increase the dynamics then also increase the number of impulses e g to 2 048 or 4 096 Use a tacho with larger number of impulses for smaller flywheels Set the following parameters in the control version async_FOC under P MOTOR DATA 1 Under Motor type set async_FOC 2 Select the tacho type used for Sensor 3 Set the number of impu...

Page 122: ...Operating Instructions 02 2019 4BS0751 007 Speed regulator circuit optimally configured Speed regulator circuit too short Tn Controller Speed regulator circuit too high P Controller The following applies to all motors Enter the rating plate parameters of the motor for sine mode This data can be found on the motor rating plate ...

Page 123: ...1 Check whether signals arrive correctly at all inputs and outputs You can simulate all data except load dependent data 2 Under P EXTRAS Menu set the value for the menu level to Standard in order to increase the number of accessible parameters and thus be able to make further parameter adjustments 7 3 Checks with mains power supply and with motor Perform the following tests and configurations with...

Page 124: ...the mains current and the motor current using a current clamp meter The measured value deviates from the displayed value on the screen depending on the type and quality of the current clamp meter 2 Ensure that the same current flows in all three mains power phases with a maximum deviation of 5 of the inverter rated current You thus detect whether damaging imbalance of the mains voltage is present ...

Page 125: ...ction of the inverter display Figure 8 1 Inverter display The display is used for operating and monitoring the inverter LEDs READY RUN and FAULT indicate the current status of the inverter The following data can be read on the plain text display The actual values of the inverter e g motor current All parameters All stored error messages ...

Page 126: ...y the speed setpoint by pressing the buttons twice This function is only active if the setpoint has been set in the configuration Use these buttons as well to select individual actual values such as e g n Motor You reach the actual values menu or one actual value menu level higher by pressing this button Press the Return button to branch into a submenu to unlock a parameter so that it can be chang...

Page 127: ...iary power sources switch this supply on first 2 Switch on the line voltage 3 Start up the inverter using the control command On or input the On command via an external control device if one is connected Shutdown 1 Stop the inverter using the control command Off or input the Off command via an external control device if one is connected 2 If you want to isolate the inverter then disconnect the lin...

Page 128: ...es Page 128 The commands have the following functions Controller enable The power unit in the converter consisting of IGBTs is only active when controller is enabled As well as the options for releasing the controller by software control cable terminal A1 X2 8 must also be activated If you deactivate this function the output semiconductor is blocked immediately and the motor coasts to a stop Speed...

Page 129: ...K2827 for a Fast stop safety related function according to IEC EN 60204 stop category one int ctr inhib If you have realized the operating functions using controls e g ON OFF button this command causes a shutdown using controller lock without deactivating the controls No new ON command is necessary for the restart int speed off This command has the same function as int ctr inhib however cause a co...

Page 130: ...ting P PARAMETER SWITCH Select the Reset source for the Reset command under P INTERFACE If you would like to activate the reset independently of the operating source changeover then set Global The reset is then possible at all operating sources 8 1 8 Invoking mode configurations Invoke the finished operating configurations under P OPERATION Opr Settings for the controls and the parameter switches ...

Page 131: ...Operation 8 1 Operation Installation and Operating Instructions SINAMICS G180 Operating Instructions 02 2019 4BS0751 007 129 8 1 9 Communication Options Figure 8 2 Communication Options ...

Page 132: ...er block for local e g s for static via control cable terminal block 2 position Speed On for local e g i for internal display via On and Off buttons 3 position Controller block for remote e g s for static via terminal block 4 position Speed On for remote e g d for dynamic via control cable terminal block You can change the operating source from local i e the inverter display to remote i e the cont...

Page 133: ...y with one PC using the PC tool IMS This is either possible via the serial interface RS 485 the optional fieldbus interfaces PROFIBUS or PROFINET For RS 485 you require an appropriate interface converter from Ethernet or USB to RS 485 and you must establish an RS 485 bus connection between the relevant converters X51 and the interface converter You must set the baud rate for all devices to the sam...

Page 134: ...lticast MAC address 01 0E CF 00 00 0x whereby x 0 Identify and x 1 Hello LLDP Link Layer Discovery Protocol Not relevant 2 Ethernet II Ethertype 0x88CC LLDP is used by PROFINET to de termine and manage relationships between the various PROFINET devices LLDP uses the special Multicast MAC address 01 80 C2 00 00 0E MRP Media Redundancy Proto col Not relevant 2 Ethernet II Ethertype 0x88E3 MRP facili...

Page 135: ...ement data to be read out and set ARP Address Resolution Pro tocol Not relevant 2 Ethernet II Ethertype 0x0806 This protocol allows the physical address of the network access layer to be determined for a network ad dress of the Internet layer SMTP Simple Mail Transfer Pro tocol 49152 4 UDP This protocol allows the PROFINET board to send emails SNTP Simple Network Time Protocol 123 4 UDP This proto...

Page 136: ... in defined protection zones Separation by means of a firewall system In the simplest scenario separation is achieved by means of an individual firewall system which controls and regulates communication between networks Separation via a DMZ network In the more secure variant the coupling is established via a separate DMZ demilitarized zone network In this case direct communication between the prod...

Page 137: ... Long distances between the device to be protected and the upstream security modules represent an invitation for data misuse Upstream security modules such as SCALANCE S must be installed close to the device to be protected in a locked control cabinet This ensures that data cannot be manipulated here without being observed 8 2 Standard mode settings 8 2 1 Mode std siss D Dynamic Pushbutton mode S ...

Page 138: ...g ramp for a fast stop The converter clears all self latching functions Reset NO Reset faults and Fast stop using a 24 V pulse at X2 14 Controller release static NC X2 8 Enable the converter using a permanent contact The drive coasts to a stop if you open the contact The converter clears all self holding functions 8 2 2 Mode std sisd D Dynamic Pushbutton mode S Static Switch mode Figure 8 4 Assign...

Page 139: ...ons S I simultaneously Control behavior for Remote static Control the operation of Speed on with a switch at X2 10 Enter the setpoint via control cable terminal block X2 with analog setpoint value 1 When required use the reversing input X2 16 Local and Remote mode Emergency stop NC If you open the contact at X2 15 the drive decelerates down to 0 speed along the braking ramp for an emergency stop T...

Page 140: ...ontact at X2 10 8 3 NAMUR mode settings 8 3 1 Operation according to NAMUR defaults If you activate the control cable terminal X2 9 with 24 V then the operating source and the setpoint input are switched from Test to Normal using a parameter switch You can connect the up and down buttons of a motor potentiometer function to control cable terminals X2 12 and X2 13 If you would like to use the motor...

Page 141: ...ow buttons Reset errors by pressing the buttons S I simultaneously The locking and the OUT input on the control cable terminal block reset the control Control behavior for normal static Control the operation of the controller release with a switch NO at X2 10 Enter the setpoint via control cable terminal block X2 with analog setpoint value 1 When required use the reversing input NO X2 16 Test and ...

Page 142: ...ording to NAMUR 2 D Dynamic Pushbutton mode S Static Switch mode Figure 8 8 Assignment of the control cable terminals for NAMUR 2 mode Operation different from NAMUR 1 The operation of the controller block for Normal mode is dynamic Start the drive with an NO normally open contact at X2 10 You inhibit the converter with a normally closed contact at X2 11 ...

Page 143: ...arrow buttons Reset errors by pressing the buttons S I simultaneously The locking and the OUT input on the control cable terminal block reset the control Control behavior for normal static Control the operation of the speed with a switch NO at X2 10 Enter the setpoint via control cable terminal block X2 with analog setpoint value 1 When required use the reversing input NO X2 16 Test and Normal mod...

Page 144: ... Operation according to NAMUR 4 D Dynamic Pushbutton mode S Static Switch mode Figure 8 10 Assignment of the control cable terminals for NAMUR 4 mode Operation different from NAMUR 3 The operation Speed On for normal mode is dynamic Start the drive with a normally open contact at X2 10 Issue the command Speed Off with an NC contact at X2 11 ...

Page 145: ... Control behavior for normal static Control the operation of the speed with a switch NO at X2 10 Enter the setpoint via control cable terminal block X2 with analog setpoint value 1 When required use the reversing input NO X2 16 Test and Normal mode Interlocking NC The controller inhibit is activated if you open the contact at X2 15 The drive coasts to a stop and cannot be restarted The inverter di...

Page 146: ... Operation according to NAMUR 6 D Dynamic Pushbutton mode S Static Switch mode Figure 8 12 Assignment of the control cable terminals for NAMUR 6 mode Operation different from NAMUR 5 The operation Speed On for normal mode is dynamic Start the drive with a normally open contact at X2 10 Issue the command Speed Off with an NC contact at X2 11 ...

Page 147: ... function of control cable terminals refer to section Standard mode settings Page 135 The function of the control cable terminals with the exception of input X2 8 for hardware shutdown is dependent on the parameterization 8 4 2 Protective separation according to EN 61800 5 1 WARNING High voltages If you connect peripheral devices which do not conform to this insulation concept equipment damage mig...

Page 148: ...ating Instructions SINAMICS G180 146 Operating Instructions 02 2019 4BS0751 007 Control and power circuits have protective separation between them according to EN 61800 5 1 The following graphics show the principle structure Figure 8 14 Overview of external connections and voltage classes ...

Page 149: ...er X101 DVC A Potential for ATV output isolating amplifier analog outputs X2 60 67 70 71 DVC A Potential for control electronics CB08 inverter electronics ext display X26 sin cos tacho X25 USB A X50A USB B X50B DVC A Potential for RS485 ext display RS232 X51 DVC A Potential SELV safety extra low voltage in accordance with EN 60950 1 BUS circuit boards DVC A Figure 8 15 Insulation concept DVC Decis...

Page 150: ... connections and DIL switches S1 1 S1 4 Hardware setting X25 SIN COS TTL speed encoder X50B USB for PC with software IMS X51 RS 485 for an external operator panel In addition it is also possible to communicate at this interface via RS 232 e g with IMS X101 HTL speed encoder X26 Additional RS 485 interface not isolated This is the standard interface for connecting the external operator panel for lo...

Page 151: ...power supply without ground connection NOTICE No supply with a power source of limited output When the connected device is overloaded the USB interface can develop defects The equipment will be damaged as a result The USB interface is a service interface only and not a general IT data interface in accordance with standard IEC EN UL 60950 1 8 4 5 DIL switches S1 and S2 Switch S1 Table 8 3 Functions...

Page 152: ...rminal X2 54 Table 8 4 DIL switch S2 can be used to set the voltage range S2 1 2 3 4 Voltage range X2 54 0 0 0 1 0 V 250 V 0 0 1 0 0 V 132 V 0 1 0 0 0 V 72 V 1 0 0 0 0 V 50 V 0 0 0 0 0 V 10 V Switch S2 5 6 7 configures the analog input AI 2 as a current voltage input PTC thermistor input KTY84 130 input or PT100 input Table 8 5 DIL switch S2 possible settings for AI 2 S2 5 6 7 Function Control cab...

Page 153: ...l only the standard control works without an encoder Note Unwanted operating state If you do not connect up the encoder cables correctly the loss of the encoder signal can give rise to unwanted operating states in the inverter control system Connecting a sincos encoder to X25 All encoder signals have a voltage level of 1 VSS The encoder connection on the motor side is designed as a socket For this...

Page 154: ...for the same encoder tracks e g A A Lay the cable shield on both sides at the encoder and inverter connector Connecting a TTL encoder to X25 All encoder signals have a voltage level compliant with RS 422 The encoder connection on the inverter side is a high density socket Only use this encoder for field oriented control with a speed accuracy 1 Connect the encoder mechanically rigid to the motor Do...

Page 155: ...ld on both sides at the encoder and inverter connector Connecting an HTL encoder at X101 Only use this encoder for field oriented control with a speed accuracy 1 Connect the encoder mechanically rigid to the motor Do not place any gearbox between encoder and motor Figure 8 20 HTL encoder at X101 In the case of making your own encoder cables only lay the shield on the inverter side 8 4 7 Connect th...

Page 156: ...sion of the installed IMS software must be Z24 or higher The USB connection feature is not available in earlier versions In the menu Options drivers select theUSB driver 8 4 8 Connecting a PC to X51 via RS 232 Figure 8 22 PC at X51 via RS 232 NOTICE Damage to the inverter electronics or the PC The pins of socket X51 are assigned signals other than those shown here Do not use a standard cable that ...

Page 157: ...for optional external display with RS 485 You have the option of connecting an external display at X51 or at X26 The connection assignment for an external display with RS 485 is shown in the following diagrams Figure 8 23 External display connected at X51 In order to be able to issue commands via an external display connected at X51 to the inverter set the corresponding command source in the param...

Page 158: ...ower side NS in short or on the motor side MS in short The P INV BEHAVIOUR MCfunc parameter specifies when the main contactor will be switched and where the main contactor must be installed Example Shutdown only in the case of an error installation on the mains power or motor side The following settings are possible Table 8 7 Contactor functions for different parameters The protection is ON for MC...

Page 159: ...or The inverter controls its own line contactor Note that the supply voltage for the control electronics is tapped before the main contactor Further information can be found in the section Connecting external control voltage for compact devices Page 111 Perform the wiring in accordance with the following plan Figure 8 25 Line contactor function ...

Page 160: ... connection switched via main contactor 8 Main contactor feedback input 55 24 V DC supply voltage 1 51 Jumper for ground connection U2 V2 W2 Motor connection NOTICE Coil currents in excess of 1 A at contact 41 42 If you load the contact 41 42 with coil currents of more than 1 A the contact can be destroyed In the case of coil currents of more than 1 A connect an auxiliary relay between terminal 41...

Page 161: ...ontactor at the inverter output Perform the activation as for the line contactor Different than for the line contactor for P INV BEHAVIOUR MCfunc as value select the parameters that have MS as prefix for motor contactor Dimension the output side contactor according to the AC3 current Perform the wiring in accordance with the following plan Figure 8 26 Motor contactor function ...

Page 162: ... CB08 More detailed information can be found in the section DIL switches S1 and S2 Page 149 The following functions are now available Analog The analog input operates as a voltage input at control cable terminals X2 52 51 54 51 or as a current input at control cable terminals X2 50 51 53 51 The value is available as AI 1 or AI 2 for further processing PTC The analog input operates as a PTC thermis...

Page 163: ... input X25 X101 is not possible e g if the n sensor is installed on the machine and there is a gearbox between machine and motor Only one simple proximity switch with e g four impulses per revolution is available The resolution for the field oriented regulation is too small in this case It is suitable for displays or more precise speed regulation You connect a frequency dependent setpoint generato...

Page 164: ...s Pulse act from 0 to 100 Connection according to connection diagram You must connect the tachometer signal at terminal X2 27 You must keep terminal X2 28 free and control terminal X2 29 with 24 V e g jumper from X2 29 to X2 55 for an evaluation as 1 track tachometer or as frequency evaluation Bit pool bits X2 27 to X2 29 PTC X2 27 and PTC X2 28 are permanently set to 0 Parameterize the following ...

Page 165: ...HTL output Figure 8 29 Digital tachometer two channel HTL level Assumption digital tachometer produces 1 024 impulses per revolution for four pole motor nmax 1500 rpm Note the following Connection according to connection diagram You must keep input X2 29 free Bit pool bits X2 27 to X2 29 PTC X2 27 and PTC X2 28 are permanently set to 0 Check the frequency in the range from 20 kHz to 205 kHz 1500 r...

Page 166: ...ify under P SPEED DEFAULT n Set source the setpoint source to which the inverter must react e g including Internal using up arrow or down arrow of the display AI 1 via analog input 1 of the control terminal block X2 BUS 1 as control word via the optional fieldbus connection 8 7 Parameterization 8 7 1 Principle of operation of the configuration NOTICE Incorrect parameter settings The converter and ...

Page 167: ... when changing the function P ContrlRelease Local you always have the selection X2 8 X2 9 Processing functions for the output are available for example P DigitalOutputs Relays 1 4 LED 1 2 or P AnalogOutputs For processing several functions are available e g P MessgGen MESS or P PARAMETER SWITCH The following graphic clarifies this processing method Figure 8 30 Configuration principle of operation ...

Page 168: ...ition of this DIL switch is described in the section Sub D connections and DIL switches Page 148 8 7 3 Configuration using the inverter display 1 You reach the configuration menu by pressing the button P The display P DRIVE DATA is shown in the first line 2 Individual menu items can be selected using up arrow and down arrow For example you reach P INTERFACE using the down arrow 3 When P DRIVE DATA...

Page 169: ...perating Instructions SINAMICS G180 Operating Instructions 02 2019 4BS0751 007 167 8 7 4 More documentation about parameterization You can find further documentation relating to parameterization on the Internet at www siemens com http www siemens com ...

Page 170: ...Examples Applications Installation and Operating Instructions SINAMICS G180 168 Operating Instructions 02 2019 4BS0751 007 8 8 Examples Applications 8 8 1 Standard application 8 8 1 1 Standard control cable terminals ...

Page 171: ...10 mA This voltage can supply a speed encoder connected at terminal X101 Remove both these jumpers if you are using peripheral boards 3 4 The supply is realized via X2 1 3 Figure 8 31 Control cable terminals for Standard application 8 8 1 2 Control cable terminals peripheral board 1 Figure 8 32 Control cable terminals for peripheral board 1 application 8 8 1 3 Control cable terminals peripheral bo...

Page 172: ...al board 3 Remove the jumper if these control cable terminals are in use X2 3 Four way distribution terminal for 24 V X2 17 18 Not assigned In the case of an equipped peripheral board 3 4 the supply of the digital inputs X2 8 16 is changed over The digital inputs are supplied from X2 1 3 instead of X2 51 55 Figure 8 34 Control cable terminals for peripheral board 3 application ...

Page 173: ...stor if these control cable terminals are in use X2 3 Four way distribution terminal for 24 V X2 17 18 Not assigned In the case of an equipped peripheral board 3 4 the supply of the digital inputs X2 8 16 is changed over The digital inputs are supplied from X2 1 3 instead of X2 51 55 Figure 8 35 Control cable terminals for peripheral board 4 application 8 8 1 6 Mode setting of the Standard applica...

Page 174: ...ripheral board 3 4 option The digital inputs are set to inactive and can thus be freely used for other configura tions 8 8 1 8 Assignment of the digital outputs Relay 1 terminal X2 37 38 39 The Ready message as changeover contact in the open circuit principle is available to you here Ready for operation means that the inverter has no faults and the DC link is preloaded Relay 2 terminal X2 41 42 Th...

Page 175: ...he Safe torque off function then you must remove this jumper and connect an NC contact of the switching element that triggers the function Terminal X2 24 This terminal can be configured as a second trigger circuit for the Safe torque off function The DIP FIX switch bail switch S3 on the peripheral board determines whether the Safe torque off function is controlled through one or two circuits S3 cl...

Page 176: ...and connect the appropriate prewarning motor PTC thermistor NOTICE Peripheral board 2 or 4 is required for monitoring The monitoring function is only available if the required peripheral board 2 or peripheral board 4 is inserted in the SINAMICS G180 If the peripheral board 1 or peripheral board 3 is installed then although the terminals are available there is no evaluation There is no monitoring D...

Page 177: ...ion 8 8 Examples Applications Installation and Operating Instructions SINAMICS G180 Operating Instructions 02 2019 4BS0751 007 175 8 8 2 NAMUR application 8 8 2 1 Control cable terminals for NAMUR application ...

Page 178: ...ormal If you use these inputs remove the jumper As long as P INTERFACE Reset Source is set to Global all reset sources are always effective Max current load of the control voltages 24 V DC potential 2 300 mA 15 V DC potential 2 150 mA 10 mA This voltage can also supply a speed encoder connected at terminal X101 Figure 8 36 Control cable terminals for NAMUR application ...

Page 179: ...e peripheral board 4 option PTC inputs suitable for motors in the Ex zone or Non Ex Zone If you use these inputs remove the jumper If you use these inputs remove the 100 Ω resistor X2 3 Four way distribution terminal for 24 V X2 17 18 For Emergency Off input In the case of equipped peripheral board 3 4 the supply of the digital inputs X2 8 to 16 is changed over The digital inputs are now supplied ...

Page 180: ...gnment of the relay outputs Terminal X2 41 42 You can control the main contactor using these terminals The main contactor function is not activated in the software for the NAMUR application For more detailed information refer to the section titled Contactor functions Page 156 Terminal X2 37 39 All warnings which are acquired in board CB08 are signaled here with a changeover contact in the open cir...

Page 181: ...meter to these terminals More detailed information can be found in the section DIL switches S1 and S2 Page 149 You can use the signal in the software for limit value comparisons or as display 8 8 2 6 Assignment of the analog outputs Isolated terminal X2 62 63 An output signal of 4 mA to 20 mA is present here This corresponds to a motor current from zero up to a unit dependent value Isolated termin...

Page 182: ...Operation 8 8 Examples Applications Installation and Operating Instructions SINAMICS G180 180 Operating Instructions 02 2019 4BS0751 007 ...

Page 183: ...self There is an appropriate maintenance schedule for each device type We recommended that maintenance is carried out at least once per year For further information please contact the Service Center see Service Support Page 189 Retighten all screw connections at regular intervals Depending on utilization the installed fans each have a service life of between 5 and 10 years The service life of the ...

Page 184: ...evice replacement screws on the outside 2 Unscrew the cover at the front 3 Slacken both the nuts of the cable entry plate in the upper connection space near the cover 4 Disconnect the power cables 5 Unplug the controller wiring connector 6 Release the fastener on the mounting plate by only slackening the screws at the bottom 7 Lift the inverter away so that the cabling remains with the cable entry...

Page 185: ...omplete system Siemens recommends that the water cooling parts are visually inspected every 6 months and a leakage check performed Perform the following checks on an annual basis Check that all of the hose clamps and valve connections that can be accessed are securely seated Perform a visual inspection of the hoses where these are visible for tears cracks or other damage We expect an average lifet...

Page 186: ...Maintenance 9 5 Decommissioning Installation and Operating Instructions SINAMICS G180 184 Operating Instructions 02 2019 4BS0751 007 ...

Page 187: ...iemens sales office responsible for your region You can find an overview of the Siemens contact partners in your region here Page 189 Always indicate the part number and if known the order number of the spare part required You can find the order number as follows The device label is attached to or next to each component Find out which item code the required spare part has The parts list provided s...

Page 188: ...Spare parts 10 2 Spare parts Installation and Operating Instructions SINAMICS G180 186 Operating Instructions 02 2019 4BS0751 007 ...

Page 189: ...or causes and rectification Errors Possible causes Fault rectification All three LEDs on the display i e READY RUN and FAULT are off dark There is no voltage at the converter Measure the control voltage at X5 see the order specific customer documentation LED READY is lit LEDs RUN and FAULT are off dark The converter cannot be started The On command does not arrive Trace the path to the converter T...

Page 190: ...otor frequency etc These data are stored for the last 64 errors The event number 01 is the most recent error Procedure Read the event log using the IMS software You can also read these data on the display Proceed as follows 1 Press I and then the down arrow until I MEMORY is shown on the screen 2 Press Return to reach the first event e g I Memory 01 Flt Undervoltage If you press Return again you c...

Page 191: ...port https support industry siemens com cs sc nId 2090 lc en WW Please have the following data ready Type Serial number You can find this data on the rating plate Contact person If you wish to request on site service or order spare parts please contact your local office This office will contact the responsible service center on your behalf You can find your contact person in the relevant contact d...

Page 192: ...tt location Germany Siemens AG Hans Loher Straße 32 94099 Ruhstorf Germany 49 8531 39 554 24 hour hotline 49 8531 39 222 0 06 min from land lines of the German Telekom mobile phone prices may differ 49 8531 39 569 Technical support driveservice rhf de siemens com Spare parts drivespares rhf de siemens com Repair driverepair rhf de siemens com Spare parts on the Internet Spares on Web www siemens c...

Page 193: ...Instructions SINAMICS G180 Operating Instructions 02 2019 4BS0751 007 191 Quality documents B You can find the quality documents here Siemens Industry Online Support SIOS https support industry siemens com cs ww en ps 13228 cert ...

Page 194: ...Quality documents Installation and Operating Instructions SINAMICS G180 192 Operating Instructions 02 2019 4BS0751 007 ...

Page 195: ...ou can find additional technical data of the inverter in the Internet with the Configurator for drive technology https eb automation siemens com goos catalog Pages ProductData aspx regionUrl de tr ee CatalogTree nodeid 10028832 autoOpenConfigId 7 kmat SD autoopen false lang uage en activetab topAnch activetab config You can also find the DT Configurator here www siemens com using the search functi...

Page 196: ...ccording to EN 60721 3 2 Vibration load Deflection Acceleration 3 1 mm at 5 9 Hz 10 m s at 9 200 Hz Shock load Acceleration 100 m s at 11 ms Chemical conditions Class 2C2 according to EN 60721 3 2 Biological conditions Class 2B1 according to EN 60721 3 2 C 2 Technical data for storage Carefully observe the following environmental conditions for storage according to EN 60721 3 1 Environmental condi...

Page 197: ...rating Instructions SINAMICS G180 Operating Instructions 02 2019 4BS0751 007 195 C 3 Frame sizes of compact units Please refer to the following diagrams and tables for the frame size of your inverter Compact device 1 dimension drawing Compact device 2 dimension drawing ...

Page 198: ...A 07600 015 2T2A 07600 022 225 665 175 650 610 100 200 320 112 5 75 BG K3 2T2A 07400 037 2T2A 07400 055 2T2A 07500 045 2T2A 07500 075 2T2A 07600 030 2T2A 07600 075 350 775 300 750 710 100 200 320 255 70 BG K4 2T2A 07400 075 2T2A 07400 110 2T2A 07500 090 2T2A 07500 132 2T2A 07600 090 2T2A 07600 132 350 1 125 300 1 100 1 060 100 200 320 255 70 BG K5 2T2A 27400 075 2T2A 27400 110 2T2A 27500 090 2T2A ...

Page 199: ...s and associated frame sizes Converter type Frame size 2R3A 87400 030 2R3A 87600 030 FS S1 2T3A 87401 200 2T3A 87401 315 2T3A 87501 250 2T3A 87501 400 2T3A 87601 250 2T3A 87601 400 2R3A 87400 055 2R3A 87600 055 FS S2 2T3A 87401 400 2T3A 87501 500 2T3A 87601 500 FS S21 2T3A 87401 500 2T3A 87401 630 2T3A 87501 560 2T3A 87501 800 2T3A 87601 560 2T3A 87601 910 FS S3 The corresponding dimension drawing...

Page 200: ... data C 4 Frame sizes of cabinet units Installation and Operating Instructions SINAMICS G180 198 Operating Instructions 02 2019 4BS0751 007 Figure C 2 Dimension drawing FS S2 Figure C 3 Dimension drawing FS S21 ...

Page 201: ...Technical data C 4 Frame sizes of cabinet units Installation and Operating Instructions SINAMICS G180 Operating Instructions 02 2019 4BS0751 007 199 Figure C 4 Dimension drawing FS S3 ...

Page 202: ... for the inverter application Climatic conditions Class 3K3 according to EN 60721 3 3 Atmospheric pressure 860 mbar 1060 mbar corresponds to max 1000 m above sea level 1 Ambient temperature 0 C 40 C 1 Humidity rating 5 95 1 g m 25 g m Mechanical conditions Class 3M4 acc to EN 60721 3 3 Vibration load Deflection Acceleration 0 075 mm at 10 58 Hz 10 m s at 58 200 Hz Shock load Acceleration 100 m s a...

Page 203: ...nnections You can unplug the plugged in connections when disconnected from the power supply When installing cables and selecting the cabling materials it is essential that you observe the information in sections Safe isolation in accordance with EN 61800 5 1 Page 145 and Connecting the control cable Page 93 The control cable terminals are color coded The green terminals on the far left contain all...

Page 204: ...l 52 and 54 or current input 0 mA or 4 mA 20 mA 100 Ω Terminals 50 and 53 Supply voltages on potential of the analog inputs for diverse sensors Terminal 55 24 V DC max 300 mA Terminal 56 15 V DC max 150 mA Terminal 57 10 V DC max 10 mA Terminal 58 10 V DC max 10 mA Digital inputs X2 27 28 Low 3 V 5 V High 13 V 32 V Floating on potential of the analog inputs Typically 2 4 mA for High Direct connect...

Page 205: ...message 3 2 kΩ 3 8 kΩ Short circuit in the sensor circuit 15 Ω 25 Ω Measuring circuit load 5 mW at R 1 5 kΩ Voltage in the sensor circuit 2 V at R 1 5 kΩ Current in the sensor circuit 1 5 mA at R 1 5 kΩ Voltage for measuring sensor break 11 6 V Current for short circuited sensor circuit 1 45 mA Response time 75 ms Electrical design Protective separation for 690 V to the other circuits according to...

Page 206: ...G S21 have the same cabinet width as the air cooled units In the case of units with frame size S3 the cabinet width when compared to the air cooled version increases as follows Cabinet increase for water cooling Units with one system 200 mm Units with two or three systems 400 mm Units with four systems 600 mm Water cooling Ambient conditions Frame size BG S2 BG S21 BG S3 Degree of protection IP55 ...

Page 207: ... ionized water for converter cooling with open standard cooling without a cooling system Material Stainless steel material number 1 4301 1 4571 Permissible values for stainless steel material Water temperature 10 30 35 C pH value 7 8 Total hardness 6 20 dH Carbonate hardness 3 10 dH Solid residue from evaporation 105 C 500 mg l Free carbon dioxide 1 mmol l Chlorides 150 mg l Sulfates 500 mg l Nitr...

Page 208: ...er or not the unit is turned on Table C 5 Threshold values for fan control system Fan fast slow off Clock enable Yes No Parameter P INVERTER DATA fan fast slow T contrl Reactor prewarning Yes No No T CPU 70 C 70 C 5 C 50 C 5 C T cabinet max 47 C 47 C 5 C 10 C 5 C T heat max 50 C 50 C 10 C 10 C 5 C T Diff max 7 9 C 1 7 9 C 1 2 C 7 9 C 1 2 C T rectif max 55 C 55 C 5 C 55 C 5 C 1 Air water cooled Whe...

Page 209: ... are not installed in a cabinet 2 Voltage derating must also be implemented for compact devices at an installation altitude of 2000 m 3 Voltage derating must also be implemented for cabinet units at an installation altitude of 3000 m The following current derating values apply to water cooled converters Refer to the technical data sheet for the maximum water intake temperature Table C 7 Current de...

Page 210: ...79 5 68 9 56 2 39 8 4001 45001 83 2 74 4 64 4 52 6 37 2 4501 50001 77 5 69 3 60 0 49 0 34 6 1 Voltage derating must also be implemented for cabinet units at an installation altitude of 3000 m Table C 9 Current derating for water cooled converters with a maximum water inlet temperature of 35 C Installation altitude above sea level in m Current derating factor in of rated current 25 C 30 C 35 C 40 C...

Page 211: ...aken into account in the voltage derating calculation Table C 10 Voltage derating for compact units Installation altitude above sea level in m Voltage derating factor in of rated voltage 0 2000 100 2001 2500 93 4 2501 3000 87 7 3001 3500 81 9 3501 4000 77 5 4001 4500 71 9 4501 5000 67 6 Table C 11 Voltage derating for cabinet units is only applicable for the basic device 1 Installation altitude ab...

Page 212: ...Technical data C 12 Derating Installation and Operating Instructions SINAMICS G180 210 Operating Instructions 02 2019 4BS0751 007 ...

Page 213: ... by one of the three European standardization committees Ex Explosion proof area FOC Field oriented control FRT Fault Ride Trough FI Frequency inverter GSD General Station Description original device master data One data format for PROFIBUS and PROFINET devices IEC International Electrotechnical Commission Standards committee for electrical engineering HVRT High Voltage Ride Trough IGBT Insulated ...

Page 214: ...ture Coefficient PTC thermistor RS 232 RS 485 RS 422 standards for serial interfaces RTU Remote Terminal Unit Remote terminal unit SELV Safety Extra Low Voltage Safety extra low voltage PLC Programmable Logic Controller STW Control word Sub D Actually D Sub common type of a connector system for data connections SVC Space Vector Control space vector modulation a technique to control rotating electr...

Page 215: ...3 Protecting 28 103 Coolant Safety precautions 20 Cooling water 205 Additives 69 D DC link terminals 52 Default setting 50 Derating 206 Current derating 206 Derating according to installation altitude 206 Temperature derating 206 Voltage derating 209 Digital inputs 161 Digital outputs 131 Display 123 External 54 installing 88 DMZ network 134 du dt filter 55 E Electrical installation 92 electronic ...

Page 216: ... 56 PROFINET board 57 Protecting the inverter 92 Protection zone 134 Protective cover 51 85 PTC inputs 47 PTC thermistor inputs 47 R Radio telephones 27 RFI suppression filter 55 S Safe halt 42 Safe torque off 39 Safety precautions Coolant 20 Safety rules 13 Service Center Ruhstorf 190 Setpoint source 164 Setting supply voltage 97 Shutdown electronic 39 Sine wave filter 55 Software Update 31 Spare...

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