Medium Voltage Variable Frequency Drive

Air Cooled: 6SR5

Medium Voltage Variable Frequency Drive

Operating Instructions

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SINAMICS PERFECT HARMONY GH180

08/2019 www.siemens.com/drives

Medium Voltage Variable Frequency DriveSINAMICS PERFECT HARMONY GH180Air Cooled 6SR5

Operating Instructions

08/2019A5E42736645A_AD

Introduction 1

Security information 2

Safety notes 3

Description 4

Preparing for Use 5

Assembly 6

Electrical Connections 7

Commissioning 8

Operation 9

Maintenance 10

Spare Parts 11

Disposal and Recycling 12

Service and Support A

Technical Data B

Quality C

List of abbreviations D

Legal informationWarning notice system

This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are graded according to the degree of danger.

DANGERindicates that death or severe personal injury will result if proper precautions are not taken.

WARNINGindicates that death or severe personal injury may result if proper precautions are not taken.

CAUTIONindicates that minor personal injury can result if proper precautions are not taken.

NOTICEindicates that property damage can result if proper precautions are not taken.If more than one degree of danger is present, the warning notice representing the highest degree of danger will be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property damage.

Qualified PersonnelThe product/system described in this documentation may be operated only by personnel qualified for the specific task in accordance with the relevant documentation, in particular its warning notices and safety instructions. Qualified personnel are those who, based on their training and experience, are capable of identifying risks and avoiding potential hazards when working with these products/systems.

Proper use of Siemens productsNote the following:

WARNINGSiemens products may only be used for the applications described in the catalog and in the relevant technical documentation. If products and components from other manufacturers are used, these must be recommended or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and maintenance are required to ensure that the products operate safely and without any problems. The permissible ambient conditions must be complied with. The information in the relevant documentation must be observed.

TrademarksAll names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.

Disclaimer of LiabilityWe have reviewed the contents of this publication to ensure consistency with the hardware and software described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in this publication is reviewed regularly and any necessary corrections are included in subsequent editions.

Siemens AGDivision Process Industries and DrivesPostfach 48 4890026 NÜRNBERGGERMANY

A5E42736645A_ADⓅ 08/2019 Subject to change

Copyright © Siemens AG 2018 - 2019.All rights reserved

Table of contents

1 Introduction...................................................................................................................................................9

1.1 Introduction ..............................................................................................................................9

2 Security information....................................................................................................................................11

3 Safety notes................................................................................................................................................13

3.1 General Safety Information ....................................................................................................13

3.2 Observing the Five Safety Rules............................................................................................14

3.3 Safety Information and Warnings...........................................................................................15

3.4 ESD-sensitive Components ...................................................................................................17

4 Description..................................................................................................................................................19

4.1 Cabinet Details.......................................................................................................................194.1.1 Supply Scope ........................................................................................................................194.1.2 Input/Output Section ..............................................................................................................194.1.3 Transformer Section...............................................................................................................194.1.4 Cell Section ............................................................................................................................204.1.5 Control Section.......................................................................................................................214.1.5.1 Control Section.......................................................................................................................214.1.5.2 Control Door Cabinet Components ........................................................................................254.1.6 Cooling Section ......................................................................................................................294.1.6.1 Cooling System .....................................................................................................................294.1.6.2 Application of Voltage ............................................................................................................294.1.6.3 Blowers and Speed Settings ..................................................................................................30

5 Preparing for Use .......................................................................................................................................31

5.1 Transportation Preparation ..................................................................................................31

5.2 Packing and Transportation Requirements............................................................................33

5.3 Proper Drives Receiving, Off-loading, Handling, Unpacking, and Placement Techniques......38

5.4 Receiving ...............................................................................................................................39

5.5 Off-Loading ............................................................................................................................40

5.6 Handling ................................................................................................................................42

5.7 Transportation with Crane......................................................................................................43

5.8 Transportation with Fork-Lift ..................................................................................................47

5.9 Transportation with Pipe Rollers ...........................................................................................49

5.10 Transportation with Roller Dollies ..........................................................................................50

5.11 Unpacking ..............................................................................................................................52

5.12 Final Placement .....................................................................................................................53

5.13 Storage...................................................................................................................................55

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6 Assembly ....................................................................................................................................................57

6.1 General Mounting ..................................................................................................................57

6.2 Proper Cabinet Anchoring Methods .......................................................................................58

7 Electrical Connections ................................................................................................................................59

7.1 General Electrical ..................................................................................................................59

7.2 Installation External Wiring ....................................................................................................60

7.3 Grounding, Cabling, and Shielding Recommendations .........................................................63

7.4 Cable Gland Plates Removal and Installation Guidelines......................................................66

7.5 Terminal Blocks......................................................................................................................67

7.6 E-Stops ..................................................................................................................................68

7.7 Associated Protection provided by the Customer ..................................................................69

8 Commissioning ...........................................................................................................................................71

8.1 Residual Current Device (RCD) Compatibility .......................................................................71

8.2 Cell Reforming .......................................................................................................................72

8.3 Pre-Commissioning Process..................................................................................................73

8.4 Pre-charge Commissioning Process......................................................................................74

9 Operation....................................................................................................................................................75

9.1 Operating the Drive ................................................................................................................75

9.2 Resetting the Protection Scheme...........................................................................................76

10 Maintenance ...............................................................................................................................................77

10.1 Introduction ............................................................................................................................77

10.2 VFD Power Down and Door Access ......................................................................................7810.2.1 Mechanical Interlock System .................................................................................................7810.2.2 Unlocking the Doors...............................................................................................................7810.2.3 Electromagnetic Door Interlock System .................................................................................81

10.3 Preventive Maintenance.........................................................................................................8210.3.1 Introduction ............................................................................................................................8210.3.2 Inspection...............................................................................................................................8210.3.3 Preventive Maintenance Checklist .........................................................................................83

10.4 Touch-Up Paint ......................................................................................................................84

10.5 Cleaning .................................................................................................................................8510.5.1 Contact for Cleaning Measures..............................................................................................8510.5.2 Removing Dust Deposits........................................................................................................85

10.6 Remove and Replace.............................................................................................................8610.6.1 Safety-relevant Checks ..........................................................................................................8610.6.2 Maintenance and Earthing Procedure....................................................................................8610.6.3 Part Replacement .................................................................................................................8810.6.4 Replacing the Filter Media .....................................................................................................8810.6.5 Replacing the Door-Mounted Keypad ....................................................................................92

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Air Cooled 6SR54 Operating Instructions, 08/2019, A5E42736645A_AD

10.6.6 Removing the Power Cell Procedure .....................................................................................9210.6.7 Replacing the Compact Flash Card (NXGpro).......................................................................9510.6.8 Installing Perfect Harmony Power Cells.................................................................................9610.6.9 Fuse Location ......................................................................................................................10210.6.10 Replacing Cell Input Power Fuses .......................................................................................10210.6.11 Cell Input Power Fuse Replacement Procedure ..................................................................10310.6.12 Printed Circuit Board Replacement Procedure (NXGpro)....................................................104

11 Spare Parts...............................................................................................................................................107

11.1 Replaceable Spare Parts .....................................................................................................107

12 Disposal and Recycling ............................................................................................................................109

12.1 Disposing of Device Components ........................................................................................109

A Service and Support .................................................................................................................................111

A.1 Field Service Operation........................................................................................................111

B Technical Data..........................................................................................................................................113

B.1 Storage, Transport and Operation Ambient Conditions .......................................................113

B.2 Power Cell Specifications Table...........................................................................................115

B.3 21/24-Cell Specifications......................................................................................................116

B.4 15-Cell Specifications...........................................................................................................117

C Quality ......................................................................................................................................................119

C.1 CE Marking and Directives...................................................................................................119

C.2 CE Marking ..........................................................................................................................120

C.3 CE Marking on Power Drive Systems (PDS) .......................................................................121

D List of abbreviations..................................................................................................................................123

D.1 Abbreviations .......................................................................................................................123

Glossary ...................................................................................................................................................129

Index.........................................................................................................................................................141

Tables

Table 5-1 Required Conditions for Transport per IEC 60721-3-2: 2018......................................................33Table 5-2 Required Conditions for Ambient Storage per IEC 60721-3-1: 2018 ..........................................55Table 7-1 Drive Torque Specifications (Zinc-Plated Hardware and Electrical Connections Only) ..............61Table 7-2 Drive Torque Specifications (Stainless Steel Hardware, Mechanical Connections) ...................61Table 7-3 Control Signal Cabling General Guidelines.................................................................................65Table B-1 General Ambient Conditions .....................................................................................................113Table D-1 Commonly Used Abbreviations .................................................................................................123

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Figures

Figure 3-1 ESD Protective Measures ...........................................................................................................18Figure 4-1 Input Protection Interface for Trip Contacts.................................................................................22Figure 4-2 Standard CIMV and TIMV Hardwired Control Signal Interface ...................................................23Figure 4-3 Input switchgear status connect circuit........................................................................................24Figure 4-4 SIMATICS Touchpad ..................................................................................................................26Figure 4-5 Multi-Language Keypad and Display Interface .......................................................................27Figure 5-1 Center of Balance Label..............................................................................................................31Figure 5-2 Securing of Uncrated Drive (blower cage removed) ...................................................................36Figure 5-3 Top to Bottom: Transportation with Crane using H-Shaped Spreader Bar; Transportation

with Crane using Single Spreader Bar .......................................................................................44Figure 5-4 Lifting Views with Typical Block Placements...............................................................................46Figure 5-5 Fork-Lift Handling (wood block view) ..........................................................................................48Figure 5-6 Fork-Lift Handling Strap/Band View ............................................................................................48Figure 5-7 Proper Placement of Pipe Rollers ...............................................................................................49Figure 5-8 Proper Placement of Roller Dollies .............................................................................................50Figure 6-1 Proper Anchoring in Concrete Technique ...................................................................................58Figure 7-1 Grounding of cable shields when multiple sections (or splices) are used...................................64Figure 10-1 DC Bus Voltage Indicator ............................................................................................................79Figure 10-2 Front View of VFD Cabinet .........................................................................................................80Figure 10-3 Attaching the grounding spider....................................................................................................87Figure 10-4 Installed Filter ..............................................................................................................................89Figure 10-5 Screwdriver Insertion Points........................................................................................................89Figure 10-6 Filter Cover Removal...................................................................................................................90Figure 10-7 Filter with Cover Removed..........................................................................................................90Figure 10-8 Filter Removal .............................................................................................................................91Figure 10-9 Fiber Optic Removal....................................................................................................................93Figure 10-10 NXGpro Digital Control Rack - Compact Flash ..........................................................................95Figure 10-11 40 A - 140 A - proper alignment of power cell mounting with receiving holes.............................97Figure 10-12 200 A - 260 A - proper alignment of power cell mounting with receiving holes...........................97Figure 10-13 Fiber Optic Location ....................................................................................................................99Figure 10-14 40 - 70 A Fiber Optic and DC Bus Indicator ..............................................................................100Figure 10-15 Torque Connections for 40 - 70 A Power Cells .........................................................................100Figure 10-16 100 - 140 A Fiber Optic and DC Bus Indicator ..........................................................................100Figure 10-17 Torque Connections for 100 - 140 A Power Cells .....................................................................101Figure 10-18 200 - 260 A Fiber Optic and DC Bus Indicator ..........................................................................101Figure 10-19 Torque Connections for 200 - 260 A Power Cells .....................................................................101Figure 10-20 Fuse Location............................................................................................................................102

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Figure C-1 CE Marking................................................................................................................................120Figure C-2 Power Drive System..................................................................................................................121Figure C-3 Drive System Schematic (Reference: IEC Std 61800-5-1-2007) Drive System Schematic ......122

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Introduction 11.1 Introduction

About This ManualThis manual provides customer documentation for the SINAMICS PERFECT HARMONY GH180 Variable Frequency Drive (VFD).

The content of this manual provides standard information as well as descriptions of all available options for this product line. The contents also provides safety warning and notes, preparation for use, assembly/installation, electrical, commissioning, operation, maintenance, spare parts, and disposal information. The latter pages of this manual contain appendices for specific technical documents, support services information, technical drawings, and other relevant data.

This manual is intended for use by trained personnel having unique job functions and qualifications since there are areas on the VFD that are hazardous and therefore may cause death or serious bodily harm to personnel and also cause serious damage to the drive.

The manual is also intended for use by planners, project engineers, installation personnel, programmers, commissioning personnel, operators, service and maintenance personnel.

This documentation contains the most important safety-related information for the SINAMICS PERFECT HARMONY GH180 VFD. It is important supplementary information, but is not a replacement for the operating instructions nor the other product documentation on your CD.

WARNING

Familiarity with the Product Documentation

Only the complete product documentation will allow you to assemble and install the equipment, to put it into operation and to maintain it correctly and safely.

Incorrect work on the equipment can result in death, severe injury or material damage.

Always refer to the operating instructions when working on the equipment. You will find the operating instructions and other equipment information about your product that you will need on the CD supplied with the Drive.

Variable Frequency Drive Introduction A variable frequency drive (VFD) system controls the rotational speed and torque of an alternating current (AC) electric motor by adjusting the frequency and voltage of the electrical power supplied to the motor. In an AC motor, frequency determines the motor speed.


Introduction1.1 Introduction


Security information 2Siemens provides products and solutions with industrial security functions that support the secure operation of plants, systems, machines, and networks.

In order to protect plants, systems, machines and networks against cyber threats, it is necessary to implement – and continuously maintain – a holistic, state-of-the-art industrial security concept. Siemens’ products and solutions only form one element of such a concept.

Customer is responsible to prevent unauthorized access to its plants, systems, machines and networks. Systems, machines and components should only be connected to the enterprise network or the internet if and to the extent necessary and with appropriate security measures (e.g. use of firewalls and network segmentation) in place.

Additionally, Siemens’ guidance on appropriate security measures should be taken into account. You can find more information about industrial security by visiting:https://www.siemens.com/industrialsecurity.

Siemens’ products and solutions undergo continuous development to make them more secure. Siemens strongly recommends you apply product updates as soon as available and always use the latest product versions. Use of product versions that are no longer supported, and failure to apply latest updates may increase customer’s exposure to cyber threats.

To stay informed about product updates, subscribe to the Siemens Industrial Security RSS Feed underhttps://www.siemens.com/industrialsecurity.


Security information


Safety notes 33.1 General Safety Information

Proper Use SINAMICS PERFECT HARMONY GH180 medium voltage drives must always be installed in closed electrical operating areas. The drive is connected to the industrial network via a circuit-breaker that is electrically connected to the VFD control to enable the drive protection features.

The specific transport conditions must be observed when the equipment is transported. The equipment shall be assembled/installed and the separate cabinet units connected properly by cable and/or busbar in accordance with the assembly/installation instructions. The relevant instructions regarding correct storage, EMC-compliant installation, cabling, shielding and grounding and an adequate auxiliary power supply must be strictly observed. Fault-free operation is also dependent on careful operation and maintenance.

The power sections are designed for variable-speed drives use with synchronous and asynchronous motors. Operating modes, overload conditions, load cycles, and ambient conditions different to those described in this document are allowed only by special arrangement with the manufacturer.

Commissioning should only be carried out by trained service personnel in accordance with the commissioning instructions.

System components such as circuit-breaker, transformer, cables, cooling unit, motor, speed sensors, etc., must be matched to VFD operation. System configuration may only be carried out by an experienced system integrator.


3.2 Observing the Five Safety RulesThere are five safety rules that must always be observed to assure not only personal safety, but to prevent material damage as well. Always obey safety-related labels located on the product itself and always read and understand each safety precaution prior to operating or working on the drive.

The five safety rules:

1. Disconnect the power applied to the system.

2. Protect against reapplication of power.

3. Make sure that the equipment is de-energized.

4. Apply grounding (earthing) means.

5. Cover or enclose adjacent components to secure all forms of hazardous energy.

DANGER

Danger Due to High Voltages

High voltages cause death or serious injury if the safety instructions are not observed or if the equipment is handled incorrectly.

Potentially fatal voltages occur when this equipment is in operation which can remain present even after the VFD is switched off.

Ensure that only qualified and trained personnel carry out work on the equipment.

Follow the five safety rules during each stage of the work.

Safety notes3.2 Observing the Five Safety Rules


3.3 Safety Information and Warnings

DANGER

Hazardous Voltage! ● Always follow the proper lock-out/tag-out procedures before beginning any maintenance

or troubleshooting work on the VFD. ● Always follow standard safety precautions and local codes during installation of external

wiring. The installation must follow wiring practices and insulation systems as specified in IEC 61800-5-1.

● Hazardous voltages may still exist within the VFD cabinets even when the disconnect switch is open (off) and the supply power is shut off.

● Only qualified individuals should install, operate, troubleshoot, and maintain this VFD. A qualified individual is "a person, who is familiar with the construction and operation of the equipment and the hazards involved."

● Always work with one hand, wear electrical safety gloves, wear insulated electrical hazard rated safety shoes, and safety goggles. Also, always work with another person present.

● Always use extreme caution when handling or measuring components that are inside the enclosure. Be careful to prevent meter leads from shorting together or from touching other terminals.

● Use only instrumentation (e.g., meters, oscilloscopes, etc.) intended for high voltage measurements (that is, isolation is provided inside the instrument, not provided by isolating the chassis ground of the instrument).

● Never assume that switching off the input disconnector will remove all voltage from internal components. Voltage is still present on the terminals of the input disconnector. Also, there may be voltages present that are applied from other external sources.

● Never touch anything within the VFD cabinets until verifying that it is neither thermally hot nor electrically alive.

● Never remove safety shields (marked with a HIGH VOLTAGE sign) or attempt to measure points beneath the shields.

● Never operate the VFD with cabinet doors open. The only exception is the control cabinet.● Never connect any grounded (i.e., non-isolated) meters or oscilloscopes to the system.● Never connect or disconnect any meters, wiring, or printed circuit boards while the VFD is

energized.● Never defeat the instrument’s grounding.● When a system is configured with VFD bypass switchgear (e.g. contactors between line

and motor, and VFD and motor), these switches should be interlocked so that the line voltage is never applied to the VFD output if the medium voltage input is removed from the VFD.

● When a system is configured with VFD pre-charge, medium voltage is present on the primary side of the input transformer and upstream device even though the MV contactor is not closed.

Safety notes3.3 Safety Information and Warnings


WARNING

Potential Arc Hazard● Arcing can result in damage to property, serious injury and even death. ● The equipment has not been tested and rated for arc flash protection.● Avoiding arc hazard risks is dependent upon proper installation and maintenance.● Incorrectly applied equipment, incorrectly selected, connected or unconnected cables, or

the presence of foreign materials can cause arcing in the equipment.● Follow all applicable precautionary rules and guidelines as used in working with medium

voltage equipment.● The equipment may be used only:

– for the applications defined as suitable in the technical description.– in combination with equipment and components supplied by other manufacturers which

have been approved and recommended by Siemens.● Always follow the facility/installation site rules/guidelines for Personal Protective

Equipment (PPE) based on the Arc Flash study of that facility.

Additional safety precautions and warnings appear throughout this manual. These important messages should be followed to reduce the risk of personal injury or equipment damage.

WARNING

Obey Rules to Avoid Risk of Death● Always comply with local codes and requirements if disposal of failed components is

necessary.● Always ensure the use of an even and flat truck bed to transport the VFD system. Before

unloading, be sure that the concrete pad is level for storage and permanent positioning.● Always confirm proper tonnage ratings of cranes, cables, and hooks when lifting the VFD

system. Dropping the cabinet or lowering it too quickly could damage the unit.● Never disconnect control power while medium voltage is energized. This could cause

severe system overheating and/or damage.● Never store flammable material in, on, or near the drive enclosure. This includes

equipment drawings and manuals.● Never use fork trucks to lift cabinets that are not equipped with lifting tubes. Be sure that

the fork truck tines fit the lifting tubes properly and are the appropriate length.

Safety notes3.3 Safety Information and Warnings


3.4 ESD-sensitive Components

Guidelines for Handling Electrostatic Sensitive Devices (ESD)

NOTICE

ESD Sensitive Equipment● Always be aware of electrostatic discharge (ESD) when working near or touching

components inside the VFD cabinet. The printed circuit boards contain components that are sensitive to electrostatic discharge. Handling and servicing of components that are sensitive to ESD should be done only by qualified personnel and only after reading and understanding proper ESD techniques. The following ESD guidelines should be observed. Following these rules can greatly reduce the possibility of ESD damage to printed circuit board (PCB) components.

● Always transport static sensitive equipment in antistatic bags.● Always use a soldering iron that has a grounded tip. Also, use either a metallic vacuum-

style plunger or copper braid when desoldering.● Ensure that anyone handling the printed circuit boards is wearing a properly grounded

static strap. The wrist strap should be connected to ground through a 1 Megohm resistor. Grounding kits are available commercially through most electronic wholesalers.

● Static charge build-up can be removed from a conductive object by touching the object with a properly grounded piece of metal.

● When handling a PC board, always hold the card by its edges.● Do not slide printed circuit boards (PCBs) across any surface (e.g., a table or work bench).

If possible, perform PCB maintenance at a workstation that has a conductive covering that is grounded through a 1 Megohm resistor. If a conductive tabletop cover is unavailable, a clean steel or aluminum tabletop is an excellent substitute.

● Avoid plastic Styrofoam™, vinyl and other non-conductive materials. They are excellent static generators and do not give up their charge easily.

● When returning components to Siemens, always use static-safe packing. This limits any further component damage due to ESD.

Components that can be destroyed by electrostatic discharge (ESD)

NOTICE

Electrostatic discharge

Electronic components can be destroyed in the event of improper handling, transporting, storage, and shipping.

Pack the electronic components in appropriate ESD packaging; e.g. ESD foam, ESD packaging bags and ESD transport containers.

To protect your equipment against damage, follow the instructions given below.

Safety notes3.4 ESD-sensitive Components


● Avoid physical contact with electronic components. If you need to perform absolutely essential work on these components, then you must wear one of the following protective gear:

– Grounded ESD wrist strap

– ESD shoes or ESD shoe grounding strips if there is also an ESD floor.

● Do not place electronic components close to data terminals, monitors or televisions. Maintain a minimum clearance to the screen (> 10 cm).

● Electronic components should not be brought into contact with electrically insulating materials such as plastic foil, plastic parts, insulating table supports or clothing made of synthetic fibers.

● Place components in contact with ESD-suited materials e.g. ESD tables, ESD surfaces, ESD packaging.

● Measure on the components only if one of the following conditions is met:

– The measuring device is grounded with a protective conductor.

– The measuring head of a floating measuring device has been discharged directly before the measurement.

The necessary ESD protective measures for the entire working range for electrostatically sensitive devices are illustrated once again in the following drawings. Precise instructions for ESD protective measures are specified in the standard IEC 61340-5-1.

1 Sitting2 Standing3 Standing/sittinga Conductive floor surface, only effective in conjunction with ESD shoes or ESD shoe grounding

stripsb ESD furniturec ESD shoes or ESD shoe grounding strips are only effective in conjunction with conductive floor‐

ingd ESD clothinge ESD wristbandf Cabinet ground connection

Figure 3-1 ESD Protective Measures

Safety notes3.4 ESD-sensitive Components


Description 44.1 Cabinet Details

4.1.1 Supply Scope

Standard Scope of SupplyThe scope of supply for the air-cooled SINAMICS PERFECT HARMONY GH180 VFD system basic unit consists of multiple sections:

● Input/Output section

● Transformer section

● Cell section

● Control section

● Blowers

The standard core VFD enclosure is ventilated, and is provided with top and bottom cable access plates, hinged doors with either mechanical or electrical key interlocks, and IP31 degree of protection.

4.1.2 Input/Output Section

Input/Output Section● The Input/Output section primarily houses the line (L1-L2-L3/U1-V1-W1) side and load (T1-

T2-T3/U2-V2-W2) side connections.

● The bus connections are accessible by way of both top and bottom gland plates.

● The I/O section also contains a protective earth (PE).

4.1.3 Transformer Section

Transformer SectionThe transformer section primarily houses the transformer and polyglass air baffling.

The air-cooled product uses an isolating multi-winding secondary phase shifting transformer. The transformer core is grounded to the enclosure.


Depending upon order specifications, the transformer is configured for 30 or 42-48 pulse power quality by using extended delta 750 V secondary windings.

The transformer is a dry type forced air-cooled unit, and polyglass air baffles are used to direct air movement across the coils. All SINAMICS PERFECT HARMONY GH180 transformers are thermally monitored.

All connections to and from the transformer are made with insulated wire. The transformer is equipped with off-line taps to accommodate utility line variations, +5%, 0%, and -5% are supplied on typical units.

Dependent upon order specifications, the winding conductor material may be aluminum or copper.

The transformers are appropriately sized for the application. However, other factors such as motor lead length, motor service factor, environment conditions, ambient conditions, altitude, and power cell redundancy must be considered.

If pre-charge function is applied, a pre-charge winding will be on the phase shifting transformer for pre-charging. V20 (VFD), pre-charge reactor, pre-charge winding, circuit breaker CDS3 and contactor M2 make up the pre-charge circuit.

4.1.4 Cell SectionThe basic electrical diagrams for all SINAMICS PERFECT HARMONY GH180 systems are similar. One of the most critical components of the drives is the power cell. The cell voltage is 750 V. Depending on the operating load voltage, 15, 21, or 24 cells are used to develop the multi-level PWM output waveform varies.

Each power cell input side is configured as a 6-pulse diode rectifier. Terminals are supplied with power via a secondary winding of the transformer. The DC output of the rectifier is filtered via the capacitor bank and supplies power to a single-phase inverter on the output side. Output terminals of each cell are connected in series in each phase group.

NoteDischarging the DC Link

The power cells include discharge resistors to dissipate stored energy after the input voltage is removed. The power cell DC bus voltage decays to less than 50 VDC in less than 10 minutes.

FusesThe secondary of the transformer is routinely fused. The fuses are mounted externally on the front panel of the power cells (located in the cell section). Only two phases of each transformer

Description4.1 Cabinet Details


secondary (power cell input) are fused. Fuses are forced air-cooled for longer life and less thermal stress.

NotePermitted Mixture of Fuse Vendors

A mixture of fuse vendors is permitted, but not within the same power cell (i.e., FA1A and FA1C should be from the same vendor).

NotePower Fuse Replacement Recommendation

As a preventive maintenance measure for drives that experience daily power cycling, Siemens recommends replacing all power fuses that have been in operation for five years.

4.1.5 Control Section

4.1.5.1 Control Section

Coordinated Input Protection SchemeThe SINAMICS PERFECT HARMONY GH180 product uses the controller with an integral I/O system. The control system continuously measures input currents and voltages to the drive's input transformer and also protects against transformer secondary side faults that cannot be seen by typical primary protection relaying. Install the drive with the input protection interface trip contacts as shown in figure Input Protection Interface for Trip Contacts. Check to ensure proper connections. Failure to install the drive with the input protection interface trip contacts as specified invalidates all standards compliance statements and all product certifications.

Information such as efficiency, power factor, and harmonics are available to the user. In the event of a fault condition, the control system provided a means of interrupting the incoming power. It is required for drive input switchgear to be interlocked to the control system to enable the means for interrupting power.

DANGER

Secondary Circuit Fault

Failure to integrate a medium voltage circuit breaking device, or contactor, may cause death, serious personal injury, and damage to the drive.

The drive's medium voltage input associated protection (examples: circuit breaker, contactor, fuses) trips when the dry contact output, supplied standard with each drive, changes state. A change of state occurs when the drive's input power and power factor do not fall within the range of designated hard-coded normal operating conditions.



① Ratings PB4E-Stop:600 VAC, 10 Amp Cont., 12 Amp make, 1.2 Amp break

② Digital Outputs:230 VAC, 1 AC

③ LFR N.C. Contacts:30 VDC and 120 VAC, 10 A100 VDC, 0.5 A240 VAC, 7.5 A

Figure 4-1 Input Protection Interface for Trip Contacts

If the drive exhibits excessive losses or reactive power, the NXG I/O digital output (M1-DOUT) is opened and the dedicated NXG I/O digital output (IDO-15) is closed as a one-shot pulse that latches the LFR coil. This action causes the Normally Closed (N.C.) LFR contact to OPEN.

DANGER

MV IP Breaker Enable

The MV IP Breaker Enable contact must be integrated with input switchgear to deactivate the drive input medium voltage up on the rare event of a secondary circuit fault.● Contacts close = Permissive to close breaker● Contacts open = Trip breaker

Failure to integrate this contact as specified may cause death, serious personal injury and damage to the drive.

MV Enable Scheme (with pre-charge function)Contactors CIMV (Close Input MV) and TIMV (Trip Input MV) provide a CLOSE and TRIP hardwired signal interface to the drive input line circuit breaker. The control of the input current interrupting devices also ensures that input power is applied only after precharging the cell DC links. The "Close Input MV" contact (CIMV), when closed, allows the application of medium voltage power to the drive. A separate status feedback signal (dry contact) must be provided from the input current interrupting device to confirm that the device is closed. The feedback signal delay must not exceed 500 milliseconds. A dry contact (Form-C) "Trip input MV" (TIMV) output is supplied standard with each drive to trip open the input current interrupting device. This contact changes status whenever a drive input protection occurs. The TIMV contact should act immediately and directly, without any interposing relays involved. Additional delays



tripping the input current interrupting device must be avoided. The input protection is defined in the NXGpro Control manual (A5E33474566).

DANGER

Integrate TIMV with Input Current Interrupting Devices

The TIMV contact must be integrated with input current interrupting the device to deactivate the drive input medium voltage upon the rare event of a secondary fault.

Failure to integrate this contact as specified may cause death, serious personal injury, and damage to the drive.

If the drive exhibits excessive losses or reactive power, the NXG I/O digital output (M1-DOUT in NXGpro) is opened and the dedicated NXG I/O digital output (IDO-15) is closed as a one-shot pulse that latches the LFR coil. This action causes the Normally Closed (N.C.) LFR contact to OPEN.

DANGER


This contact must be integrated with input switchgear to deactivate the drive input medium voltage up on the rare event of a secondary circuit fault.● Contacts close = Permissive to close breaker● Contacts open = Trip breaker

Figure 4-2 Standard CIMV and TIMV Hardwired Control Signal Interface



Note● Contact rating 110 VDC 1 A● This signal MUST be integrated into the drive main input line circuit breaker● Dashed line = wiring by customer● Normally Open, Normally Closed contact designated by customer

Input MV circuit breaker status signal, input switchgear working position signal and ground switch status signal must be connected to NXG I/O digital input (default is IDI-3D, it can be changed in the S-drawing and SOP) as one of the signal to judge all pre-charge conditions have been ready and can start pre-charging.

DANGER

Integrate input MV circuit breaker status signal, breaker working position signal and ground switch status signal as one of the pre-charge permission condition

This contact must be integrated with input switchgear to prevent pre-charge action if input switchgear has not been ready for pre-charge. And if any of these signals are on wrong status, pre-charge action must be stopped.● Input MV circuit breaker status contacts close = Input MV circuit breaker is open● Input switchgear working position contacts close = Switchgear is on working position● Ground switch status contacts close = Ground switch in switchgear is open● Input MV circuit breaker is open & switchgear is on working position & ground switch in

switchgear is open = One of this pre-charge permission signal is ready.

X7-19 +24V

-K25

DI-3D

X2-54 +24V

X7-18 0V

-K25

Figure 4-3 Input switchgear status connect circuit



Terminal BlocksThe drive uses 8 mm, 600 V terminal blocks from the auxiliary input three-phase voltage (used primarily for blower control). These terminals accept #8 - #22 AWG wire.

The single-phase control terminal blocks accept #12 - #22 AWG wire.

Auxiliary Voltage TransformerThe auxiliary voltage transformer steps customer-supplied three-phase auxiliary voltage down to a single-phase 220 V for use with an NXG controller.

NoteSelection of Auxiliary and Control Voltage Supply

When Auxiliary and Control Voltage Supply Option is selected, control power will be supplied by the customer's power source and auxiliary transformer will be installed.

4.1.5.2 Control Door Cabinet Components

SIMATIC Keypad User Interface (for OI)The drive is equipped with a keypad and display interface located on the front of the drive control cabinet. Refer to the manual entitled "NXGpro Control " (A5E33474566) for detailed information on keypad operation.



Keypad Function

Figure 4-4 SIMATICS Touchpad

Use the keypad to:

● navigate through the menu system

● activate control functions

● reset the system after faults have occurred

● edit parameter values

● enter security access codes

● start or stop the drive when in local control

● acknowledge alarms



ML User Interface Multi-Language Keypad (T76)The drive is equipped with a keypad and display interface located on the front of the drive control cabinet (for above 3000 m option).

Figure 4-5 Multi-Language Keypad and Display Interface

The multi-language keypad is intended as a direct replacement for the standard keypad. The electrical connection and mechanical fit/mounting are the same between the multi-language keypad and the standard keypad.

Keypad FunctionsUse the keypad to:

● navigate through the menu system

● activate control functions

● reset the system after faults have occurred

● edit parameter values

● enter security access codes

● start or stop the drive when in local control



Push button kit (option K29)The components of the pushbutton kit in the control cabinet door panel:

● a START pushbutton

● a STOP pushbutton

● a fault reset button

● a manual speed potentiometer

Off-Local-Remote Selector Switch (option K31)The Off-Local-Remote Selector is the default three-position mode select switch that is mounted on the front of the drive. If the switch is in the OFF position, the inverter output is inhibited. If the switch is in the Remote position, the control uses either a remote 4-20 mA DC speed demand or a network demand, depending on how the project SOP is written. Local mode operation occurs if SW1 is not in the OFF or Remote position; and, the speed demand is set by the keypad operator.

Off-Hand-Auto Selector Switch (option K32)The Off-Hand-Auto Selector is a three-position mode select switch that is mounted on the front of the control door. If the switch is in the OFF position, the inverter output is inhibited. If the switch is in the Auto position, the control uses either a remote 4-20 mA DC speed demand or a network demand, depending on how the project SOP is written. Hand mode operation occurs when SW1 is not in the OFF or Auto position; and, the speed demand is set by the keypad operator.

Keyed Off-Local-Remote Selector Switch (option K33)The Keyed Off-Local-Remote Selector is a three-position mode select switch provided with keyed protection. The switch is mounted on the front of the drive. If the switch is in the OFF position, the inverter output is inhibited. If the switch is in the Remote position, the control uses either a remote 4-20 mA DC speed demand or a network demand, depending on how the project SOP is written. Local mode operation occurs if SW1 is not in the OFF or Remote position; and, the speed demand is set by the keypad operator.

Keyed Off-Hand Auto Selector Switch (option K34)The Keyed Off-Hand-Auto Selector is a three-position mode select switch provided with keyed protection. The switch is mounted on the front of the control Door. If the switch is in the OFF position, the inverter output is inhibited. If the switch is in the Auto position, the control uses either a remote 4-20 mA DC speed demand or a network demand, depending on how the project SOP is written. Hand mode operation occurs if SW1 is not in the OFF or Auto position; and, the speed demand is set by the keypad operator.



Ethernet PortEthernet Port is included on the front of the control door. The port can be used for debug support and uploading / dowloading data communications with the NXG controller.

NoteUse of Ethernet Port

This port is for maintenance use only. This port is secured by physical access only. Connection of this port to any network is strongly discouraged.

4.1.6 Cooling Section

4.1.6.1 Cooling System

Cooling System Components The cooling system consists of several parts including blower(s). Each blower has a suitably rated three-phase combination starter (circuit breaker & contactor combination). There is an optional line reactor that is connected upstream to the combination starter in the circuit that feeds an optional EMI filter.

Cooling System Function The cooling system functions as follows:

● The line reactor connects to a combination starter (circuit breaker & contactor combination). The contactor is controlled through the SOP of the NXG controller.

● The output of the combination starter (circuit breaker & contactor combination) connects to quick disconnect plugs which connect individual blowers to the power source.

● The default SOP logic is configured to operate the blower immediately when control power is energized.

● If the blower (or blowers) fails or loses power, the SOP logic controller issues a drive trip. This fault condition must be manually reset.

● For units with pre-charge, blowers are de-energized during a pre-charge start, then re-energized upon the completion of successful pre-charge.

4.1.6.2 Application of VoltageControl power must always be applied prior to application of medium voltage.



4.1.6.3 Blowers and Speed Settings

BlowersAll SINAMICS PERFECT HARMONY GH180 air-cooled drives are force air-cooled.

An extremely important part of the installation process is making provisions for exhausting the heat that is generated by the operation of the drive. Although the drive is highly efficient, there may be as much as several hundreds kilo watts energy loss emitted in the form of heat from inside the system cabinet. This heat must be transmitted to the outdoor air or into the structure of the building at a rate fast enough to prevent the ambient temperature from rising above the rated conditions.

NoteAir Inlet Cooling

The customer is responsible to ensure proper cooling is provided at the inlet of each drive.

The drive is a parallel path forced air-cooled system using across-the-line blower(s). Each of the cells and the transformer are cooled by centralized exhaust blower(s).

The cell section and transformer section exhaust air into an air duct. Each cell’s input and output power connections are made at the front of the cell means of bolted connections. The bolted connections are located in line with the inlet air of the cell. For systems with mechanical cell bypass, the contactors are mounted on the front panel of the power cells, located in line with the inlet air of the cell. All of the bus and the contactors are therefore forced-air cooled, at ambient temperature. Two phases of each cell’s inputs are fused. The fuse ambient is the same as the cell inlet air temperature.

If redundant blowers are provided, a cover plate is removed from the top of the enclosure and a redundant blower cage assembly is installed. Dampers are installed at the front of the redundant blower cage to prevent reverse air flow. The dampers are opened and closed based on differential air pressure. The blower assembly design consists of a steel frame or cage with mesh at the bottom side (duct interface jobs require alternative pre-engineered blower module).

Air is exhausted out of the front of the blower section in standard configuration products. Air will be exhausted out of the back of the blower section only when rear ducting option is selected.

Provision is provided to cycle redundant blowers periodically by means of the control interface from the NXG control.

CAUTION

Never energize the drive without operational blowers providing air flow.

When power is applied to the drive that is operating in an IDLE condition state, blowers must be operational to remove heat generated by component losses. Failure to provide air flow for heat dissipation could result in damage to the drive or its components.

Applying Medium Voltage without air flow will result in a trip from the Coordinated Input Protection Scheme.

To remove the unit's latent heat, Siemens recommends running the blower for ten minutes after removing Medium Voltage.



Preparing for Use 55.1 Transportation Preparation

Safety Information and Precautions InformationPlease note the following:

● "Transportation Unit" refers to the drive cabinet before it has been unpacked.

● "Cabinet" refers to the drive cabinet after it has been unpacked.

● Review the drive specific Shipping and Handling Guidelines and General Handling Guidelines that are provided with the SINAMICS PERFECT HARMONY GH180 package. These documents are attached to the enclosure of each transportation unit.

Weight and Dimensions of the Transportation Unit/CabinetRefer to the Bill of Lading or Packing List provided with the drive to view the weight and dimensions of each transportation unit/shipping split. Contact Siemens if any of the documents mentioned in the previous paragraphs are not available.

Center of Balance of the Transportation Unit/Cabinet

Figure 5-1 Center of Balance Label

The original packaging of the drive contains labels that show the center of balance of the transportation unit. Always take the center of balance into account when lifting and installing the cabinet. Refer to specific drawings, located inside of the cabinet, provided with the drive. Ensure that the turning radius of the selected forklift truck will not impedemanueverabilit.

Shipping SplitsStandard shipping split configurations for GH180 drives differ based on the type of cooling, the current rating, and the number of power cells. The SINAMICS PERFECT HARMONY GH180 is a customized product. Shipping split configurations can vary from drive to drive. Refer to the System Lifting Instruction Drawings provided with the drive to determine the shipping split configuration.

6SR5 Air-Cooled (40 - 260 A, 15-cell)1. Fan assemblies shipped on pallets

2. Transformer & Cell cabinet


6SR5 Air-Cooled (40 - 140 A, 21-cell and 24-cell)1. Fan assemblies shipped on pallets

2. Transformer & Cell cabinet

6SR5 Air-Cooled (200 - 260 A, 21-cell and 24-cell)1. Fan assemblies shipped on pallets

2. Transformer cabinet

3. Cell cabinet

NoteCell Shipment

Cells may be shipped separately in some instances.

Examples: ● Cell(s) ordered as spare part● Project specific requirements

Preparing for Use5.1 Transportation Preparation


5.2 Packing and Transportation Requirements

Minimum Packing RequirementsUncrated cabinets need to be completely covered in plastic and must be stretch-wrap sealed around the sides.

For water, air, and rail transport, the equipment must be packaged in a solid wall crate adequately constructed to support the equipment. Additionally, the equipment must be sealed in a moisture vapor barrier that is supported by an appropriate level of moisture inhibiting material (e.g., dessicant).

Packaging maintenance may be required during transit or storage. Packaging maintenance includes, but is not limited to, the following examples:

1. Vapor barrier repair or replacement if barrier seal is damaged during transport or opened for inspection.

2. Replacement of desiccant material if product will be exposed to high moisture environment for an extended period of time. Refer to packaging labels and drawing instructions provided with your specific system for guidance on proper strap locations.

3. Repair or replacement of pallet or base frame if damaged and no longer capable to support safe, reliable equipment lift or transport.

4. Repair or replacement of crating material if damaged and no longer capable to provide protective environment for equipment.

Contact Siemens when extended periods of storage or exposure to extreme environmental conditions occur.

Transportation Requirements1. Siemens references the environmental industry standard of IEC 60721-3-2 when shipping

SINAMICS PERFECT HARMONY GH180 drives.

2. Ensure precautions are made to minimize the risk exposing internal enclosure components to water, moisture and chemicals.

Table 5-1 Required Conditions for Transport per IEC 60721-3-2: 2018

Required Conditions for TransportConditions Class Exception

Climatic 2K12 Mechanical 2M4 No free fall permitted.

No stacking permitted.Tilt and Roll angle limited to 10 degrees, which equates to mod‐erate seas.

Biological 2B1 Chemically Active Substances 2C2 Product must be weather protected during transportation. For

additional details refer to the section Transport of SINAMICS PERFECT HARMONY GH180 Drives.

Preparing for Use5.2 Packing and Transportation Requirements


Required Conditions for TransportMechanically Active Substances 2S1 Product must be weather protected during transportation. For

additional details refer to the section Transport of SINAMICS PERFECT HARMONY GH180 Drives.

Other per IEC 61800-5-1Degree of Pollution 2 Drive must be sealed in the presence of conductive pollution.

Transport of SINAMICS PERFECT HARMONY GH180 Drives

Truck, Trailer, and Lorry Transport1. Where available, air ride trailers are recommended.

2. Use full length tarps to completely cover the load (crated or uncrated).

3. If securing over the top of uncrated cabinets, strap positioning should be should be toward the four corners of the shipping split to prevent bending.

4. If using chains through the fork pockets, chain protectors should be used to minimize damage to the finish/paint.

5. When crated, large crates are not stackable. Please comply with do not stack warning labels.

6. Crates cannot be breached or altered when securing.

7. Equipment cabinets or crates should sit flat on the deck of the trailer. If equipment elevation or suspension is necessary, adequate support under the entire load is required.

8. If protective barrier packaging is opened or damaged during transit (i.e. actions to perform inspection by Customs), inspection and repackaging should be completed immediately to correct packaging damage and mitigate potential risk for equipment damage. Equipment damage caused by damaged or missing protective packaging is not covered by Siemens warranty policy.

Ocean and Air TransportCrated and packaged equipment is designed for ocean transport and meets all 2M4 conditions with the exceptions of free fall and pitch and roll.

1. All Truck, trailer, and Lorrie Transport requirements must be met.

2. Crating and moisture vapor barrier supported by an appropriate level of moisture inhibiting material are required. All minimum packing requirements must be met.

3. "Out of gauge" ocean cargo shipping by means of open top containers, flat racks, mafis or break bulk must be stowed below deck.

4. Crates must sit flat on the floor of the flat rack, mafi, open top or vessel. If equipment elevation or suspension is necessary, adequate support under the entire load is required.

5. If protective barrier packaging is opened or damaged during transit (i.e. actions to perform inspection by Customs), inspection and repackaging should be completed immediately to correct packaging damage and mitigate potential risk for equipment damage. Equipment damage caused by damaged or missing protective packaging is not covered by Siemens warranty policy.



Rail Transport1. All Truck, trailer, and Lorrie Transport requirements must be met.

2. Notify Siemens if rail transport will be used prior to order placement. Special transport packaging or equipment design may be required.

3. Crating and moisture vapor barrier supported by an appropriate level of moisture inhibiting material are required. All minimum packing requirements must be met.

4. Crates must sit flat on the deck of the rail car. If equipment elevation or suspension is necessary, adequate support under the entire load is required.

WARNING

Equipment may be subjected to shock and vibration

When using rail transport, equipment may be subjected to shock and vibration level that exceeds equipment and packaging design specification criteria thus voiding Siemens warranty coverage.

Securing the LoadPrior to moving or transport, the load must be secured using the following methods:

● Use appropriate retaining straps to secure the load and prevent tipping.

● Use positive locking on the loading surface, for example, by wedging the unit/cabinet on the truck loading surface to prevent shifting.

● Fit spacers under gaps to support the weight.

● Use chains through the fork tubes with appropriate chain protectors.

NoteWarranty Disclaimer

Failure to obey these requirements VOIDS your Siemens warranty coverage.

If you are unsure of YOUR SPECIFIC WARRANTY REQUIREMENTS, contact Siemens.

Illustration ExamplesThe following illustratons provide examples for how to strap and secure uncrated SINAMICS PERFECT HARMONY GH180 drive products and shipping split configurations.

Product configurations and packaging varies by product. Refer to caution labels affixed to the cabinets and shipping splits for proper strap locations for your specific system.



Figure 5-2 Securing of Uncrated Drive (blower cage removed)

Handling RequirementsThe handling requirements are as follows:

● Lifting and handling equipment is not provided by Siemens.

● Lifting cabinets or caged units may require use of a spreader bar.

– Refer to lifting guidelines using notations posted on cabinets or crates.

– Refer to product manual for additional guideline details.

– Lifting and handling uncrated units require use of bubble-wrapped wood blocks to prevent cabinet damage.

● Cabinet and crated unit lifting may have significantly offset centers of gravity.

– For uncrated cabinets, following lifting guidelines posted on the cabinets.

– For crated items, follow lifting marks and notations marked on the crates.

● Siemens recommends periodic inspections of equipment or packaging during shipment and storage.



WARNING

Properly Lift or Transport Equipment1. Care and attention must be used to continuously monitor lift conditions while lifting. Use

low lifting heights and slow movements where possible when lifting or transporting equipment.

2. Lifting and transport equipment must be sized appropriately (for forces to which they will be subjected).

WARNING

Ensure Transportation is in Accordance with Proper Procedures

The transportation unit/cabinet is heavy. The equipment may tip over if not transported correctly, or, if an unpermitted method of transport is used.● Ensure that the transportation unit/cabinet is transported by trained personnel only. ● Use only recommended methods of transport and lifting equipment.● Always position the cabinet in the proper upright position.● Never tip the cabinet.

Failure to obey these warnings may result in death or serious injury to personnel and material damage to the drive.



5.3 Proper Drives Receiving, Off-loading, Handling, Unpacking, and Placement Techniques

When handling SINAMICS PERFECT HARMONY GH180 drives, it is essential to understand the proper techniques associated with:

● Receiving

● Off-loading

● Handling

● Unpacking

● Placement

These topics are discussed in the sections that follow.

Preparing for Use5.3 Proper Drives Receiving, Off-loading, Handling, Unpacking, and Placement Techniques


5.4 Receiving

Receiving

Perform the steps of the receiving procedure as indicated below. 1. Verify that the proper items have been shipped.

2. Do not remove the packaging until immediately prior to installation.

3. Inspect all items for damage that may have occurred during shipping, handling, or storage.

4. Do not discard packaging if damage is found. If any damage is present, immediately file a claim with the shipping carrier. The carrier for shipment damage is responsible for processing shipment damage claims and it is the carrier's terms & conditions that must be followed. (inclusive of time limitations to submit a claim & requirements to view crating & packaging). For other specific order information, contact Siemens.

NoteDamage During Shipment

If damage occurs during shipment, contact the shipping carrier to file a claim. For technical assistance, call Technical Support - Worldwide Centers (+86 021 58585775).

Preparing for Use5.4 Receiving


5.5 Off-LoadingOverviewSiemens recommends completion of installation site review prior to receipt of equipment. Performing the review helps to ensure no access restrictions exist that will prevent transport or installation, such as low ceiling height or narrow door width.

Off-loading from the truck is often the most critical operation because in many situations the available space is minimal and careful maneuvering must be employed. Advance planning and coordination among the manufacturer, the carrier, the installation contractor are vital.

NotePrior to Moving the Unit

Before moving the unit, verify the following:● The units doors are closed/installed.● The unit is in an upright position.● The unit is stabilized to prevent tilting.

After off-loadingAfter off-loading, if the drive will be placed upon ground that is not flat and stable a stable, level foundation must be established to prevent risk related to the cabinet tipping and falling or damage to the cabinet from torsional stress. If suspension above the ground is required to prevent ingress of water or other undesirable conditions, Siemens recommends the drive be rested on wooden or steel blocks with 0.5 m maximum spacing intervals. Blocks must support the entire depth of the cabinet and be at least 1/5 longer than the depth of the cabinet/transportation unit depth. Ensure the base is stable, flat and level after placement on blocks to prevent risks such as tipping or potential cabinet structure damage.

If multiple section drives will be off-loaded directly to their final installation location, the customer must first decide the order of placement prior to initiating uncrating and transport to minimize handling steps and risk for damage. (Example: Right to left or left to right installation placement)

CAUTION

Possible damage when transporting and placing cabinet sections

Care must be taken when transporting and placing cabinet sections to avoid dropping or jarring actions which could damage the drive cabinet or its contents.

CAUTION

Possible exposed wires/cables

Drive may be delivered with exposed wires/cables. Care must be taken to prevent damage to wires/cables during lifting and installation processes. (for example, pinching cables or damaging cable insulation)

Preparing for Use5.5 Off-Loading


Note

SINAMICS PERFECT HARMONY GH180 drive system is a customized product. Exact weights for shipping sections can vary. Refer to the System Lifting Instruction Drawings provided with the drive for the estimated weights and center of gravity for your specific system.

Preparing for Use5.5 Off-Loading


5.6 HandlingThe following list shows the allowable methods of handling cabinets:

1. Crane with Strap and Cradle

2. Fork Lift Truck Lifting

3. Pipe Rollers

4. Roller Dollies

Each method is discussed in the subsequent sub-sections of this chapter.

NoteLIFTING LIABILITY● Personnel performing lifting and handling of equipment load has liability for managing safe

transport.

To help assure proper lifting of cabinets, Siemens suggests the following actions:

● Verify that the equipment used is sized appropriately according to weights and forces to which they will be subjected.

● Continuously monitor the actual lifting process.

● Use slow movements and low lifting heights where possible.

Preparing for Use5.6 Handling


5.7 Transportation with Crane

Transportation with Crane

WARNING

Failure to Transport in Accordance with Proper Procedures

If not properly transported with crane, the transportation unit/cabinet may tip over or fall, which may result in death, serious injury, or equipment damage.

The recommended lifting method for standard shipping is the strap and cradle method. The strap and cradle method of transportation employs the use of fabric slings through the lifting openings in the cabinet base to lift cabinets. The length and tensile strength of the slings are crucial to this method of lifting.

1. Read all available safety information about crane transportation before actually using a crane for transporting units/cabinets.

2. Ensure that the lifting equipment is undamaged.

3. Do not exceed the permissible transportation weight of crane.

4. Locate the center of balance and center of gravity of the unit prior to lifting the transportation unit/cabinet and lift using a spreader bar and sling. In most cases, the center of balance will be off-center and must be considered prior to lifting.

5. Ensure that slings are at least 1.3 m (51 in) above the top of the enclosure.

6. Use spreader bars (singled or H-shaped depending on cabinet size) to prevent damage to the cabinet/unit. The illustration "Transportation with Crane using H-shaped and Single Spreader Bars", depicts proper spreader bar use.

7. Ensure that the strength of the sling is adequate for the weight specified in the dimension drawing(s) for your specific order.

8. Adjust sling length to compensate for a displaced center of gravity.

Preparing for Use5.7 Transportation with Crane


9. Lift the transportation unit/cabinet using the sling.

10.Ensure that the unit/cabinet is parallel to the ground. Failure to perform this step may cause damage to occur.

Figure 5-3Top to Bottom: Transportation with Crane using H-Shaped Spreader Bar; Transportation with Crane using Single Spreader Bar

①Spreader Bar②Centroid③Center of Gravity



Transportation with Strap and CradleThe strap and cradle method of transportation employs the use of fabric slings to lift cabinets. The length and strength of the slings are crucial to this method of transportation.

WARNING

Improper Use of Strap and Cradle

Ensure that the load carrying capacity of the hoisting equipment is adequate for the weight specified in the order specific lifting diagram furnished by Siemens.

Death or serious injury to personnel, or damage to the cabinet/unit may result if the load carrying capacity of the equipment is inadequate.

CAUTION

Potential Damage to Drive Cabinets

To prevent buckling of the drive cabinets, the slings must be of adequate length; and, spreader bars must be of appropriate strength.

Strap and Cradle Procedure

NoteWeight of Populated Drives

Exact weights of systems will vary based on the ratings of the drive and the included options.For customized drives having switchgear or transitions cabinets, refer to the project drawings supplied with the drive.

WARNING

Center of Gravity Offset

Units with more than one cabinet including the transformer cabinet have a significantly offset center of gravity. This center of gravity is skewed toward the transformer unit/cabinet.

Ensure great care is taken when determining the length and positions of the lifting straps.

Death or serious injury to personnel, or damage to the cabinet/unit may result if the load carrying capacity of the equipment is inadequate.

Lifting Unit with FiltersPlace blocks of wood encased in bubble wrap between the cabinet and the straps. The following photographs show additional lifting views with typical block placements.



Figure 5-4 Lifting Views with Typical Block Placements



5.8 Transportation with Fork-Lift

WARNING

Fork-Lift Considerations and Guidelines● Use only appropriately rated fork-lifts to lift and transport unit/cabinet.● Ensure fork-lift forks/tines are of proper size for fork-lift tubes; and, maintain the proper

lifting capacity for the specific drive.● Review travel conditions such as floor consistency and ramp angles (stress and balance)

and correct conditions prior to lifting or moving equipment.● Use low lifting heights and slow movements where possible when lifting or transporting

equipment.● Be sure to center and position the transportation unit/cabinet as close to the front axle of

the fork-lift as possible. ● Take into account that fork-lifts require large spaces for safe lifting and turning. Siemens

recommends completion of installation site review prior to receipt of equipment to ensure no access restrictions exist which will prevent transport or installation.

Death or serious injury to personnel, or damage to the transportation unit/cabinet may result if these guidelines are not obeyed.

WARNING

Do Not Exceed Maximum Lift Height Guideline● Lifting transportation unit above the maximum lift height is dangerous. Be aware of any

obstacles that may require lifting over the safe height lift guideline. ● Lifting above the maximum height lift guideline may cause the transportation unit/unit

cabinet to tip over, resulting in death or serious injury to personnel, or damage to the transportation unit/cabinet.

1. Except as noted within System Lifting Instructions provided with your specific drive order, only fork-lift tubes may be used for lifting and transport. Cabinet floor is not designed to support the load for lifting cabinet and must not be used for lifting or transport.

2. Load should be secured prior to lifting or transport to prevent tipping movement or dropping.

Preparing for Use5.8 Transportation with Fork-Lift


3. Forks/tines must protrude at the rear of the transport unit/cabinet.

4. Place a wooden stop block between fork lift frame and unit base frame to prevent surface damage to the unit. Refer to the figure Fork-lift Handling.

Note

Ensure fork-lift truck can still maintain protrusion of fork tips.

①②③

Fork-lift TruckWood BlockSide of Truck

Figure 5-5 Fork-Lift Handling (wood block view)

①②③

Fork-lift TruckStrap/BandSide of Truck

Figure 5-6 Fork-Lift Handling Strap/Band View

Preparing for Use5.8 Transportation with Fork-Lift


5.9 Transportation with Pipe Rollers

WARNING

Improper Drive Foundation

Ensure that the ground is stable. If the ground is soft, lay a "trackway" by using rails, bars, or boards. Trackway must not be able to sink causing an un-level surface.

Ensure that the foundation for the drive is level and flat. Any sloping can cause the drive to tip or fall over.

If the foundation is unstable and/or not level, death, serious injury, or damage to the cabinet unit may result.

When space constraints prohibit using a crane, lift the cabinet onto rollers.

It is possible to set the enclosure on many parallel pipe sections placed on the floor and then move it by rolling.

Note

Use thick-walled steel pipes. Other suitable pipes are round steel rods, round timber rods, or concrete-lined pipes.

Ensure pipes are at least 6 cm (2.36 inches) thick and are at least 1/5 longer than the transportation unit/cabinet depth.

The pipes must be spaced no more than 45.72 cm (18 inches) apart.

Pipe Rollers Procedure1. Raise the transportation unit/cabinet.

2. Place pipes under the unit/cabinet.

3. Ensuring that it will not cause damage to the enclosure, use pry-bars, hoists, or a pulley system when moving the unit/cabinet on rollers.

4. Roll the unit/cabinet to the installation location.

5. Raise the unit/cabinet slightly and remove the pipes.

Figure 5-7 Proper Placement of Pipe Rollers

Preparing for Use5.9 Transportation with Pipe Rollers


5.10 Transportation with Roller Dollies

WARNING

Improper Drive Foundation

Ensure that the ground is stable. If the ground is soft, lay a "trackway" by using rails, bars, or boards.

Ensure that the foundation for the drive is level and flat. Any sloping can cause the load to tip or fall over.

If the foundation is unstable and/or not level, death or serious injury to personnel, or damage to the cabinet unit may result.

When space constraints prohibit using a crane, lift the cabinet from the pallet onto roller dollies.

NoteWeight Rating

Be sure that the weight rating on the roller dolly complies with the weight specifications on the dimension drawings shipped with the drive.

Roller Dollies Procedure1. Place roller dollies under the front and rear channels of the base, as close as possible to the

outside edge of the fork-lift tubes and beneath the shipping splits.

2. Raise the transportation unit/cabinet and then place the roller dollies under it.

3. Ensuring that it will not cause damage to the enclosure, use pry-bars, hoists, or a pulley system when moving the unit/cabinet on roller dollies.

4. Roll the transportation unit/cabinet to the installation location, making sure to comply with the safety rules and guidelines.

5. Raise the transportation unit/cabinet and remove roller dollies.

Figure 5-8 Proper Placement of Roller Dollies

Preparing for Use5.10 Transportation with Roller Dollies


WARNING

Improper Use of Dollies

When handling the unit/cabinet, check the load plate to verify that the dollies are designed to carry the load.

Ignoring guidelines for proper use of dollies may cause death or serious injury to personnel, or cause damage to the cabinet unit.

Preparing for Use5.10 Transportation with Roller Dollies


5.11 Unpacking

NoteComply with All On-Site Requirements

Siemens recommends that the operating areas be dry and free of dust. The environment should not contain any electrically conductive gas, vapors, or dust, which could impair operation.

Upon receipt of the drives:

1. Perform a visual inspection to assure shipment is not damaged.

2. Verify that all items are received.

3. Carefully remove the plastic wrap and load securing devices.

4. Do not remove the packaging until immediately prior to installation.

5. If equipment will not be placed in operation after installation, cover louvers and external openings to prevent entry of dust, moisture, and contaminants. In addition to covering louvers and openings, Siemens recommends covering the equipment cabinet with a tarp or protective cover.

6. Packaging material should not be discarded if filing for a shipment damage claim is required. If no shipment damage claim is required, discard the packaging material in accordance with the applicable country-specific guidelines and rules.

7. Prior to commissioning, protect the cabinets against dust, moisture, and contaminants by covering the ventilation opening and keeping the doors/panels closed.

8. Do not remove handling and storage instructions from the cabinet(s).

NoteDamage During Shipment

If damage occurs during shipment, contact the shipping carrier to file a claim. For technical assistance, call Technical Support - Worldwide Centers (+86 021 58585775).

Preparing for Use5.11 Unpacking


5.12 Final Placement

Placement ProcedureAfter final inspection, promptly move the drive to its final position or environmentally controlled dry indoor storage area. Comply with the steps indicated below:

1. Place the equipment in a clean, dry, and level place. Refer to floor flatness requirements in the mounting information noted below.

2. Check to ensure adequate space is provided for access to perform drive maintenance and to meet local safety requirements. Refer to drawings provided with your specific system for minimum access space required for the SINAMICS PERFECT HARMONY GH180 drives you purchased.

3. Ensure that the ambient temperature throughout the storage period does not fluctuate by more than 0.5 °C/min according to IEC 60721-3-1.

4. Always protect stored equipment so that it is protected from contamination and ambient influences. This rule is essential for long periods of storage time. Refer to Chapter Storage of this manual for additional storage data.

NoteMounting Information● Mount the SINAMICS PERFECT HARMONY GH180 drive on a flat surface. The drive

mounting surface must satisfy a floor flatness number (Ff) of 38 (min. local, 32) and a floor levelness number (Fl) of 25 (min. local, 20) as per ACI 117-90 Section 4.5.6.1 (as measured in accordance with ASTM E 1155-87).

● If the mounting surface is not flat and the cabinet structure becomes twisted, the cabinet may become misaligned and impact the capability for doors and door interlocks to operate properly. Shims may be required to align the drive cabinet for proper operation of the doors and door interlocks.

After off-loadingAfter off-loading, if the drive will be placed upon ground that is not flat and stable a stable, level foundation must be established to prevent risk related to the cabinet tipping and falling or damage to the cabinet from torsional stress. If suspension above the ground is required to prevent ingress of water or other undesirable conditions, Siemens recommends the drive be rested on wooden or steel blocks with 45.72 cm (18-inch) maximum spacing intervals. Blocks must support the entire depth of the cabinet and be at least 1/5 longer than the depth of the cabinet/transportation unit depth. Ensure the base is stable, flat and level after placement on blocks to prevent risks such as tipping or potential cabinet structure damage.

If multiple section drives will be off-loaded directly to their final installation location, the customer must first decide the order of placement prior to initiating uncrating and transport to

Preparing for Use5.12 Final Placement


minimize handling steps and risk for damage. (Example: Right to left or left to right installation placement)

CAUTION

Possible damage when transporting and placing cabinet sections

Care must be taken when transporting and placing cabinet sections to avoid dropping or jarring actions which could damage the drive cabinet or its contents.

CAUTION

Possible exposed wires/cables

Drive may be delivered with exposed wires/cables. Care must be taken to prevent damage to wires/cables during lifting and installation processes. (Example: cutting or abrasion of wire/cable insulation).

Note

SINAMICS PERFECT HARMONY GH180 drive system is a customized product. Exact weights for shipping sections can vary. Refer to the System Lifting Instruction Drawings provided with the drive for the estimated weights and center of gravity for your specific system.

Preparing for Use5.12 Final Placement


5.13 StorageThe following paragraphs provide the necessary information for storage of SINAMICS PERFECT HARMONY GH180 drives after completion of inspection. Storage information includes, but is not limited to:

● Crated and/or wrapped equipment prior to installation.

● Installed, but not commissioned or operational equipment.

● Commissioned and operational equipment that will sit idle or not be used.

Storage● Refer to the IEC Standards IEC 60721-3-1 table for ambient conditions for storage.

● Equipment cabinets or crates should sit flat on the deck or ground. If equipment elevation or suspension is necessary, adequate support under the entire load is required.

● Siemens recommends equipment is stored in an environmentally controlled warehouse to ensure specified environmental conditions can consistently be met.

● Equipment vents, louvers, and openings should be covered to protect ingress of moisture and contamination if equipment removed from crate and protective packaging.

● Recommend use of full length tarps to completely cover equipment (crated or uncrated).

● If exposed to ambient conditions of high humidity or moisture, protective measures are required. (Example: desiccant, dehumidifier, or temperature controlled strip heater)

● Maintenance may be required for extended periods of storage, or when exposed to extreme environmental conditions.

● Liquid cooled units filled with liquid must have pumps running to circulate coolant during extended periods of idle operation or storage.

Note

If the drive is de-energized (or in storage) for 24 or more months, the SINAMICS PERFECT HARMONY GH180 cell electrolytic capacitors must be reformed.

Contact Siemens (+86 021 58585775) about reforming procedures. Unqualified personnel are NOT permitted to reform cells as failure to follow reforming procedures may result in cell or system damage.

Table 5-2 Required Conditions for Ambient Storage per IEC 60721-3-1: 2018

Ambient Conditions for StorageRequired Climatic Conditions for StorageAmbient Temperature +5 °C to +40 °CRelative Air Humidity < 95 %

(No condensation permitted; converter must be completely dry before commissioning)

Preparing for Use5.13 Storage


Ambient Conditions for StoragePower Cell Storage Temperature -25 °C to +60 °C (-13 °F to 140 °F)Other climatic conditions in accordance with class Classified as 1K21 1 and 1Z2 in accordance with IEC 60721-3-1: 2018Degree of pollution 2

Without conductive or statically charged semi-conductive pollution in accordance with IEC 61800-5-1: 2007

Required Mechanical Conditions for StorageRandom vibration curve 1.0 m2/s3 (10 to 100 Hz)

-3.0 dB/octave.Hz (100 to 200 Hz)0.5 m2/s3 (200 to 2000 Hz)

Other mechanical conditions in accordance with class

Classified as 1M12 in accordance with IEC 60721-3-1: 2018and 2M1 in accordancce with IEC 60721-4-2: 2003-2

Other Required Ambient Conditions for Storage 2

Biological ambient conditions in accordance with class

Classified as 1B1 in accordance with IEC 60721-3-1: 2018

Chemical active substances in accordance with class

Classified as 1C2 in accordance with IEC 60721-3-1: 2018

Mechanical active substances in accordance with class

Classified as 1S10 in accordance with IEC 60721-3-1: 2018

1 Class 1K21 applies to enclosed storage locations with limited temperature control and no humidity control. 2. When brass gland plates are used, environments containing ammonia must be avoided.

Preparing for Use5.13 Storage


Assembly 66.1 General Mounting

Standard Work PracticePrior to performing any type of work on the equipment, refer to the "Safety Notes" chapter of this manual.

Handling and Mounting the DriveAdhere to the following general information with respect to installation:

● The cabinets must be installed in accordance with the guidelines in this manual.

● Protect the VFD against excessive mechanical stress and torsional loading.

● Drives are designed to be accessed from the front side (for installation and service).

Installing the VFD at its Final Location

NoteMechanical Damage

Strain occurring during transport and installation can exert mechanical pressure on the components.● Align cabinets to relieve mechanical stresses and avoid shearing forces created when

cabinet bases are bolted together.

Failure to comply with the above statement may result in mechanical damage.

NoteMounting Information

Mount the SINAMICS PERFECT HARMONY GH180 drive on a flat surface. The drive mounting surface must satisfy a floor flatness number (Ff) of 38 (min. local, 32) and a floor levelness number (Fl) of 25 (min. local, 20) as per ACI 117-90 Section 4.5.6.1 (as measured in accordance with ASTME 1155-87).

Failure to comply may cause mechanical damage to the drive and may also negatively affect overall system performance.


6.2 Proper Cabinet Anchoring MethodsHoles for anchor bolts are located on the base mounting channel typically 1" (25.4 mm) from front and back edges, and 4" (102 mm) from the sides. Refer to supplied drawings for mounting details.

When anchoring the cabinets to the floor, we recommend that the installer use cemented J-bars on all corners. Holes in the base of the drive cabinets are 0.875" (22.3 mm) in diameter and easily accept 0.5" (12.7 mm) threaded J-bars. If the drive is mounted against a wall, top angles may be used to secure the drive to the back wall in lieu of the rear J-bar connections to the floor. Refer to the figures shown below for an overview. Exact dimensions are given in the drawings supplied with the drive.

Note

Refer to the system drawings provided with the VFD for the type of base structure used with the cabinet as well as the exact connection locations.

Figure 6-1 Proper Anchoring in Concrete Technique

Note

Given the location of the blower assembly, wall anchoring may require enclosure drilling modifications.

Assembly6.2 Proper Cabinet Anchoring Methods


Electrical Connections 77.1 General Electrical

Standard Work PracticePrior to performing any type of work on the equipment, refer to the "Safety Notes" chapter of this manual.


7.2 Installation External Wiring Customer-supplied medium voltage cables enter an access plate in the top or bottom.

Customer-supplied low-voltage cables (#8 - #22 AWG) for the control enter an access plate in the top or bottom. Refer to the project drawings for exact locations.

The input and output medium voltage terminals (L1, L2, L3 and T1, T2, T3) are offset from one another and can adapt to top or bottom cable termination.

VFD

OBJECTINPUT 1 OUTPUT PROTECTIVE CON‐

DUCTOR

Maximum Cross-Section

ofExternal Wires

15 cells 40 - 70 (76) A 1 x 70 mm2 1 x 2/0 AWG

1 x 35 mm2

1 x 1 AWG70 mm²2/0 AWG

100 - 140 A 1 x 185 mm2 1 x 350 MCM

1 x 35 mm2 1 x 1 AWG

70 mm2 2/0 AWG

200 - 260 A 1 x 185 mm2 1 x 350 MCM

1 x 95 mm2 1 x 4/0 AWG

70 mm2 2/0 AWG

21 cells 40 - 70 (76) A 1 x 70 mm2

1 x 2/0 AWG1 x 35 mm2


100 - 260 A 2 x 240 mm2

2 x 500 MCM1 x 95 mm2

1 x 4/0 MCM70 mm²2/0 AWG

24 cells 40 - 70 (76) A 1 x 70 mm2 1 x 2/0 AWG

1 x 35 mm2


100 - 260 A 2 x 240 mm2

2 x 500 MCM1 x 95 mm2

1 x 4/0 AWG70 mm²2/0 AWG

1 The actual cross-section of input wire is not necessarily the maximum vaule. When input and output voltages are same, the cross-section of the input wire and the output wire should be kept same.

NoteIndividual conductor breakdown for three-conductor single-core cables

The SINAMICS PERFECT HARMONY GH180 drive design is best accommodated for single-conductor single-core medium voltage cables.

NoteCable length rules

For long length cable application, 21-cell system cannot be used for the length of cable longer than 2 km.

Electrical Connections7.2 Installation External Wiring


Table 7-1 Drive Torque Specifications (Zinc-Plated Hardware and Electrical Connections Only)

Fastener Size Tightening Torque ValueEnglish Metric Newton-Meters

(Nm)FT-LB IN-LB

2-56** M2 0.4 3.04-40** M3 0.7 6.06-32** M3.5 1.4 12.08-32** M4 2.5 22.0, (15.0)**10-32 M5 4.0 36.01/4-20 M6 8.0 72.01/4-28 8.0 72.05/16-18 M8* 17.0 156.03/8-16 M10* 31.0 276.03/8-24 31.0 276.01/2-13 M12 76.0 56.0 5/8-11 153.0 112.0 3/4-10 270.0 198.0

1-8 600.0 480.0 * These values do not apply when this hardware is used on power modules, such as IGBTs, and diodes). For the required torque values in these instances refer to the System drawings provided with the drive.** These sizes are only torqued when used on ground wire.*** #8 bolts used in secondary connections on CTs are torqued to 15 in-lbs.

NoteInput Conductor Sizing

Be sure to size the input conductors appropriately for the particular application, taking into account the length of the input power feed as well as local electrical code and local standards. Labels located near the connections recommend the use of 75 ○C conductors.

Table 7-2 Drive Torque Specifications (Stainless Steel Hardware, Mechanical Connections)

English Sizes Metric Sizes (mm)

Newton-Meters(Nm)

FT-LB IN-LB

10-32 5 271/4-20 6 7.2 645/16-18 8 12.7 9 1123/8-16 10 22.7 17 200*7/16-14 --- 36.2 27 3201/2-13 12 50.2 37 4449/16-12 14 65.1 48 5765/8-11 16 105.8 78 936



English Sizes Metric Sizes (mm)

Newton-Meters(Nm)

FT-LB IN-LB

3/4-10 18 146.4 108 1296 20 333.5 246 2952

7/8-9 22 223.7 165 1980--- 24 542.3 400 4800

1-8 (1.0) 27 329.5 243 2916*CTs that are mounted with 3/8 inch bolts will only be torqued to 100 in-lbs.



7.3 Grounding, Cabling, and Shielding Recommendations

NOTICE

Adherence to Local Safety Regulations

Understand and obey all local safety regulations with regards to grounding. Recommendations do not supersede safety grounding regulations.

VFD GroundingThe variable frequency drive as a whole should be bonded to the facility ground using the following two methods:

● Bond the VFD at one point only using the shortest cable length. The VFD cabinet to facility ground connection shall be properly sized per local codes or regulations.

– The connection can be made in the VFD either in the input cabinet or in the output cabinet.

– In the event of ground faults, the peak current and duration are much greater for the input than the output. Therefore, it is preferable to ground the VFD in the input cabinet to minimized the fault current flowing through the cabinet to cabinet connections.

● If a grounding grid is available under the VFD, the VFD cabinet can be solidly grounded to the facility ground structure at multiple points.

Neither the SINAMICS PERFECT HARMONY GH180 transformer primary neutral point on the input, nor the medium voltage output neutral point, shall be bonded to ground.

If used, the precharge winding shall be resistance grounded.

Motor GroundingThe motor case must be bonded to facility ground using the shortest cable length.

Bearing Currents:

● If machine induced bearing currents are of concern, then isolated bearings on the non-drive end of the motor shaft can be implemented.

● Siemens recommends using a shaft ground brush on the drive-end of the motor shaft when concerns exist regarding whether the rotating load or the drive could cause harmful bearing currents.

● The encoder must be electrically isolated from the motor shaft.

Electrical Connections7.3 Grounding, Cabling, and Shielding Recommendations


VFD Output CablesThe following recommendations apply when the VFD is grounded to the facility ground though a single connection at either the input cabinet or at the output cabinet:

● Ground output cable shield connections only on the VFD end using short lead lengths, preferably shorter than 61 cm (24 in). Multiple ground connections on output cables can cause circulating currents that may elevate the potential on the ground bus in the VFD cabinet. The elevated potential could introduce noise into the control section of the VFD.

● It is not necessary to ground the cable shields at the motor end, unless a customer specific safety requirement exists.

● When multiple cable sections are used in series, each cable section should have its VFD end of the shield grounded. Refer to the figure Grounding of cable shields when multiple sections (or splices) are used.

NoteLong Length Cable Application

For long length cable application, 21-cell system cannot be used for the length of cable longer than 2 km.

Figure 7-1 Grounding of cable shields when multiple sections (or splices) are used

When the VFD is solidly grounded to the facility ground structure at multiple points, the following recommendations apply:

● Shield connections of the output cables may be grounded at both ends using short lead lengths, preferably shorter than 61 cm (24 in).

● The cable shields at the motor end may be grounded.

● When multiple cable sections are uses in series, then each cable section may have the shield connections grounded at both ends.

VFD Input CablesThe input cable shields may be grounded at either end. Consult the local codes and regulations for guidance.



Encoder Feedback, Analog I/O, and Digital I/O Signals into the VFD● Fully shielded cable must be used for analog I/O and low voltage (< 50 V) digital I/O wiring

to the VFD. For isolated I/O, the shield must be grounded at only the VFD. Twisted pair should be used for applications using differential signaling or when the return path of the signal is also present.

– The shield grounding termination point should be at the customer terminal strip point of cable entry to the cabinet.

● 220 VAC digital I/O driven by semiconductor based switches (not dry contacts) must use twisted shielded pair with a return path per signal.

● Check customer-side wiring for 'ground loops' (should be avoided).

● Do not install cable with MV wiring. Siemens recommends installing the cable in a separate metal conduit.

● Install digital and analog signals in separate metal conduit from each other and from the power wiring.

Note

Minimum shielding assumes foil shield with drain wire. Siemens recommends using double shielding using foil and braid.

● The shield connections of all the WAGO I/O need to terminate at a common point on the drive end. Test shield connection (using ohm meter) to verify a good connection.

● Encoder applications assume a galvanically isolated encoder using HTL quadrature output.

Table 7-3 Control Signal Cabling General Guidelines

Signal Type Cable Recommended Termination PointAI Twisted Shielded Pairs* VFDAO Twisted Shielded Pairs* VFDDI (24 V) Twisted Shielded Pairs VFDDI (120 V) Twisted Shielded Pairs VFDDO( 24 V) Twisted Shielded Pairs VFDDO (120 V) Twisted Shielded Pairs VFDCR3 (24 V) Twisted Shielded Pairs VFDCR3 (120 V) Twisted Shielded Pairs VFDNotes:*Best Practice is to use cable with double shielding.All signals specified in the above table are galvanically isolated.References: GAMBICA Variable Speed Drives and Motors; Installation Guidelines for Power Drive Systems Fourth Edition, 2012

VFD Customer 3-Phase Control CablingThe 3-phase control cable wiring to the VFD must use fully shielded cable with shield grounded at the VFD only.

Each customer input section is supplied with a ground pad (lug).



7.4 Cable Gland Plates Removal and Installation Guidelines

Cable Gland Plates Removal and Installation GuidelinesRemoval of gland plates is necessary to complete input and output power cable installation. Gland plates are attached to the drive enclosure and can be removed by unfastening the hardware.

Gland Plate Installation Preparation and Procedure:1. Place the unfastened hardware in a safe place to allow for quick retrieval when re-installing

the gland plates.

2. Fit the cable entries with a proper water-tight seal.

3. If cable size permits, make holes for drilling cable entries.

4. Do not drill the gland plate while it is still mounted to the enclosure.

NOTICE

Gland Plate Drilling

Do not drill the gland plate while it is mounted to the enclosure.

Drilling the plate while it is mounted leads to metal dust accumulation on sensitive electronics that are located inside of the unit, which may cause loss of component integrity and possibly affect system operability.

Gland Plate Drilling Guidelines1. Take care not to damage the rubber gasket seal material during the drilling process.

2. Fit the cable entries with a proper water-tight seal.

3. Ensure that gland plates are properly fastened to the drive with the original hardware.

4. Confirm rubber gasket seal integrity prior to installing the gland plate.

NoteMaintain IP Rating of Enclosure

To maintain the IP rating of the enclosure/cabinet, a proper gasket seal is required.

Inspect for any damaged gasket prior to and after installing the gland plates.

Electrical Connections7.4 Cable Gland Plates Removal and Installation Guidelines


7.5 Terminal Blocks

Terminal BlocksRefer to the Control Section of this manual for specific information about terminal blocks.

NoteSpare Terminal Availability

Consult Siemens for customized systems requiring additional terminals.

DANGER

Electrical Hazard!

Standard safety precautions and local codes must be followed during installation of external wiring.

Protective separation must be kept as specified in IEC 61800-5-1.

Electrical Connections7.5 Terminal Blocks


7.6 E-StopsRefer to the section of this manual entitled "Control Section" for information about E-Stop incorporation into the Coordinated Input Protection Scheme.

Electrical Connections7.6 E-Stops


7.7 Associated Protection provided by the CustomerTo ensure adequate protection for VFDs, the associated protection (that is, the circuit breaker or fused contactor) provided by the customer must fulfill the following requirements:

● The rated interrupting time of the associated protection shall not exceed 100 ms (duration between trip to no-current state).

● A feedback signal must be provided from the associated protection to indicate the status - CLOSED or OPEN.

● The associated protection is activated and enabled by the VFD closed-loop controller. It must never be switched on by any other method when connected to the VFD.

● An overcurrent protection device must be provided to protect the VFD.

● The master mechanical interlock key (K1) must be coordinated with the associated protection.

● This device is considered the main upstream isolating/disconnecting means for the equipment and is subject to the local governing electrical codes (e.g., NEC, CED, EU norms).

Electrical Connections7.7 Associated Protection provided by the Customer


Electrical Connections7.7 Associated Protection provided by the Customer


Commissioning 88.1 Residual Current Device (RCD) Compatibility

CAUTION

RCD Incompatibility

Connecting this device to a power supply protected by a residual-current device can result in damage to property and minor personal injury.

This product can produce a DC current in the grounding conductor.

When using a Residual Current Device (RCD) in cases where direct or indirect contact can be made, only a Type-B RCD shall be permissible on the line side of this product. If this is not possible, an alternative means of protection must be applied. Isolation from the environment through double or reinforced insulation, or isolation from the power supply using a transformer, is an example of alternative means of protection.


8.2 Cell Reforming

NOTICE

Reform Capacitors Schedule

If capacitors have been out of service for more than 24 months, they must be reformed. This will assure the electrolytics are not in a degraded state and will perform at the level needed for optimal drive performance.

Power Cell Capacitor ReformThe capacitors can be reformed with the cell in or out of the drive. If reformed out of the drive, each cell must be reformed one-at-a-time. If reformed in the drive, then all the cells can be reformed at the same time.

WARNING

Unqualified personnel are NOT permitted to reform cells.

Only qualified personnel may perform cell reforming. Potential electrical hazards and physical injury, including death, can occur when the voltage is applied to a Power Cell that is outside of the Cell Cabinet enclosure.

Please contact the Siemens factory for further information about the Power Cell Reforming.

Commissioning8.2 Cell Reforming


8.3 Pre-Commissioning ProcessPerform the necessarry steps to complete the pre-commissioning process:

1. The customer must review the pre-Commissioning Checklist Air Cooled VFD Commisioning Requirement and prepare the VFD for the commisioning procedure.

2. Ensure the Pre-Commissioning checklist procedure is complete prior to arrival of Qualified Siemens Personnel for commisioning of the VFD.

NoteThe VFD must be commissioned by Qualified Siemens Personnel only.

Commissioning8.3 Pre-Commissioning Process


8.4 Pre-charge Commissioning ProcessIf pre-charge is applied and pre-charge model is used, perform below commissioning process. Pre-charge circuit consists of V20 (VFD), pre-charge reactor, pre-charge winding, circuit breaker CDS3 and contactor M2. V20 commissioning and programing is completed in Siemens factory. Any change for V20 is not allowed. If there is any problem, contact Siemens for support.

1. To start pre-charge, ensure that power is available to the input MV power supply and LV power supply.

2. Energize 380 VAC and 220 VAC power supply until control system is normal.

3. Set CDS3 to reset status, and then close CDS3 circuit breaker.

4. Verify that the H1 indicator is turned on. (This will indicate that the system is ready to pre-charge.)

5. Press PB20 momentary pushbutton for local control to start pre-charge.

6. When accessing the system remotely, press the remote control pushbutton to start pre-charge.

DANGER

Unqualified personnel are not permitted to change V20 program

Some pre-charge logic has been programmed into V20. After the drive is delivered from Siemens factory, any parameter change for V20 is not permitted. If any maintenance is required for V20, contact Siemens for support.

Non-Siemens engineer changing of V20 parameter may cause death, serious personal injury, and damage to the drive.

Commissioning8.4 Pre-charge Commissioning Process


Operation 99.1 Operating the Drive

Prior to performing any type of work on the equipment, refer to the "Safety Notes" chapter of this manual.

The VFD must be commissioned by Qualified Siemens Personnel only.

DANGER

Qualified Personnel ONLY

Only trained personnel may operate a SINAMICS PERFECT HARMONY GH180. Improperly operating the drive can cause damage to property, serious injury, and possible death.

Refer to the manual entitled "NXGpro Control " (A5E33474566) for detailed information on operating the drive.


9.2 Resetting the Protection Scheme

Protection Scheme Reset Procedure

DANGER

Reset Protection Scheme Caution

Failure to obey all safety precautions may cause death and equipment damage and drive failure. Prior to resetting the protection scheme, refer to the section of the NXGpro Control Manual titled "Troubleshooting Faults and Alarms", and then contact Siemens technical personnel. ( +86 021 58585775) Refer to the Appendix "Service and Support".

Resetting the protection scheme1. In the control section, reset the LFR/K1 using SW2/K2 or keyed reset pushbutton. The LFR/

K1 N.C. contacts are immediately reclosed.

2. Initiate a "Drive Fault Reset". The control will not re-close M1_DOUT (NXGpro) if the fault conditions still exist. Refer to the NXGpro Control Manual (A5E33474566).

DANGER


This contact must be integrated with input switchgear to deactivate the drive input medium voltage upon the rare event of a secondary circuit fault. Failure to do so may result in death, and equipment damage.● Contacts close = Permissive to close breaker● Contacts open = Trip breaker

Note

Given the amperage rating of the components used in the coordinated input protection scheme, an additional customer pilot relay may be required.

Operation9.2 Resetting the Protection Scheme


Maintenance 1010.1 Introduction

The SINAMICS PERFECT HARMONY GH180 drive is designed, built, and tested to provide long, trouble-free service. Keeping the drive working reliably, minimizing system down time, and maintaining safety, requires periodic maintenance.

Prior to performing any type of maintenance, be sure to read all relevant safety and product information. Perform procedures as indicated. Refer to the chapter in this manual titled Safety Notes.

DANGER

Electrical Hazard!

High voltages are present within this equipment which could cause death or serious injury if safety instructions are not observed.

Always switch off the main input power to the equipment, and follow the safety guidelines defined in the Safety Notes chapter of this manual and in local codes before attempting inspection or maintenance procedure.

Ensure that only qualified and trained personnel carry out work on the equipment.

WARNING

Qualified Personnel Only

Due to the modularity of the SINAMICS PERFECT HARMONY GH180 variable frequency design, the maintenance and earthing procedure does not cover all variations of equipment types or installations. Refer to Figure: Drive System Schematic and the factory drawings furnished with each drive.

Siemens strongly recommends that only qualified personnel be allowed to perform maintenance on SINAMICS PERFECT HARMONY Systems.

Refer to Appendix Service and Support for customer service contact information.


10.2 VFD Power Down and Door Access

10.2.1 Mechanical Interlock SystemThe drive can be locked mechanically using a key interlock system. For safety, the drive may be delivered with a key transfer system that interlocks the doors to restrict personnel access.

Operation1. Switch OFF (open) the drive input disconnect.

2. Apply the LOTO (Lock-Out-Tag-Out) procedures as required by local code.

3. The coded K2 keys from the drive input disconnect can now be removed from the interlock key transfer.

10.2.2 Unlocking the DoorsThe doors of the VFD must not be opened until the following statuses are present:

1. The EMERGENCY STOP push-button on the control section door has been activated.

2. The key-operated switch on the control section door has been set to OFF position.

3. A delay time of 10 minutes from the time of de-energization of the incoming power to the VFD, to the time the VFD doors can be opened, has occurred.

4. The DC-link voltage has been de-energized.

NoteDC Bus-Voltage Indicator LED must NOT be illuminated.

The DC Bus-Voltage Indicator LED, located on the front of each cell's Cell Control Board, must NOT be illuminated. An illuminated DC bus voltage-indicator LED shows that more than 50 VDC is present on the DC bus. This indicator light may not be visible until the cell doors are opened.

5. Do not touch, remove, or service the power cells if the LED indicator is illuminated.

6. If mechanical lock is chosen, use the coded K1 key (released from the customer circuit breaker) to release the K2 keys for the cabinet door (located in the key transfer unit on the VFD).

7. If mechanical lock is chosen, the K2 keys released for the cabinet doors can be used to unlock the doors of the VFD.

Maintenance10.2 VFD Power Down and Door Access


WARNING

Discharging Resistors

The power cells include discharge resistors to dissipate stored energy after the input voltage is removed.

The power cell DC bus voltage decays to less than 50 VDC in less than 10 minutes.

Obey all safety precautions to avoid risk of death, serious personal injury, and equipment damage.

Figure 10-1 DC Bus Voltage Indicator



Figure 10-2 Front View of VFD Cabinet



Opening the Door for the Control CabinetThe control section door on the drive can be opened while the drive is in operation.

NoteClosing the Circuit Breaker

All access keys from the cabinet must be returned to the key transfer unit. Upon returning the access keys, the coded key (K1) will be released for the circuit breaker. The circuit breaker cannot be closed until the coded key (K1) is returned.

10.2.3 Electromagnetic Door Interlock System

Electromagnetic Door Interlock System The electromagnetic door interlock system is designed to protect personnel and is an integral part of the safety concept. During operation and when the make-proof grounding switches (if applicable) are open, all the doors are interlocked (with the exception of the door for the control section).

The electromagnetic door interlock system ensures that the doors for the power unit cannot be opened when the voltage at the drive is still above a defined threshold value.

The electromagnetic door interlock system guarantees that the doors can only be opened after the doors have been released by the software. They are not released unless the protection and monitoring sequence has been observed.

The drive cannot be switched on again until all the doors are closed and if applicable, the make-proof grounding switches are open.The doors remain interlocked if the auxiliary voltage fails.



10.3 Preventive Maintenance

10.3.1 IntroductionThe preventive maintenance chapter applies to drive operation, drive storage, and spare parts.

10.3.2 InspectionRegularly scheduled inspections are required to evaluate the current status of your equipment. Customer inspection actions are comprised mainly of visual checks.

Note

For complete inspection information, Siemens Customer Service support is required. Call Technical Support - Worldwide Centers (+86 021 58585775).

Maintenance10.3 Preventive Maintenance


10.3.3 Preventive Maintenance ChecklistUse the table below as a guide for performing preventive maintenance tasks.

Maintenance Performed by: Frequency CommentsClean the cabinet (exterior). Operator As required Visual check, clean if required.Clean the cabinet (interior). Operator Annually Visual check, clean if required.Check the electrical con‐nections (external power and test connections) and check the cable/screw ter‐minals.

Operator After 1 yearand then every 6 months or as needed

Check the cable and screw termi‐nals regularly to ensure that they are secure. If they are not secure, tighten them according to specifi‐cations.

Check the internal connec‐tions.

Operator After 1 yearand then every 6 months or as needed

Visual check, clean if required.

Carry out inspection and visual check.

Operator Annually See the specifications in the oper‐ating manual.

Check the software. Siemens serv‐ice personnel

Whenever parameters are changedand then every 5 years.

Measure the capacitors. Siemens serv‐ice personnel

After 3 yearsand then every 2 years.

Check operation of bypass contactors (if installed).

Siemens serv‐ice personnel

After 3 yearsand then every 2 years.

Visually inspect the insula‐tion

Operator Annually

Check the filters Operator Every 6 months or as site conditions warrant.

Refer to the section of this manual titled "Replacing the Filter Media".

Dampers Operator Every 6 months Visual checks for cracks and for damaged or loose parts.

Air-Air Heat Exchanger (Option Code M58)

Operator As required Visual check, clean if required

Note

The actual intervals at which maintenance procedures are to be performed depend on ambient environmental and operating conditions for your specific installation.

Siemens offers its customers support in the form of a service contract. For further details, contact your regional office or sales office.

Maintenance10.3 Preventive Maintenance


10.4 Touch-Up Paint

Touch -Up PaintUse touch-up paint, as needed, on any rusty or exposed parts on the cabinet enclosure. Clean surface of any rust prior to painting.

Maintenance10.4 Touch-Up Paint


10.5 Cleaning

10.5.1 Contact for Cleaning MeasuresIf contamination occurs, contact Siemens customer service. Refer to the appendix "Service and Support".

10.5.2 Removing Dust Deposits

Dust Deposits Dust deposits inside the cabinet unit must be removed at regular intervals (or at least once a year) by qualified personnel in accordance with the relevant safety regulations.

● Use only a soft bristle, anti-static brush to loosen the dust particles.

● Do not use a vacuum cleaner directly on components.

● Only use dry compressed air (maximum 1 bar) from a distance no less than 6 inches from components.

Maintenance10.5 Cleaning


10.6 Remove and Replace

10.6.1 Safety-relevant Checks

WARNING

Visual Check of Cable Insulation

Improperly installed cables, damaged or defective cables, and incorrectly terminated cable shields can cause short-circuits or arcing which can create hot spots and cause fires.● Check power cables to confirm the insulation is not damaged or defective.● Ensure that the cable shields are intact. ● Insulate shields that are damaged.

NoteComponent Replacement

Unless otherwise indicated by Siemens, always replace components with the same part number and revision level or newer.

NoteDrive Failure

When the power supply is switched off, data about error message statuses is lost.

For additional technical support, contact the Siemens Service Center.

NoteDoor Interlock Failure

Contact Siemens Service Center for technical support.

10.6.2 Maintenance and Earthing Procedure

WARNING

Qualified Personnel Only

Due to the modularity of the SINAMICS PERFECT HARMONY GH180 VFD design, the Maintenance and Earthing Procedure does not cover all variations of equipment types or installations. Siemens strongly recommends that only qualified personnel be allowed to perform maintenance on SINAMICS PERFECT HARMONY systems.

Maintenance10.6 Remove and Replace


Perform the steps in the order as indicated below:1. To ensure statuses as described are in place, read the VFD Power Down and Door Access

chapter of this manual prior to opening the doors of the VFD,

2. Apply Green/Yellow insulated ground cables from L1/L2/L3 and T1/T2/T3 to protective earth, P.E. Refer to the section of the manual entitled "Grounding, Cabling, and Shielding Recommendations" that can be found in the chapter entitled "Electrical Connections". Be sure to obey all local codes strictly for grounding.

3. Perform maintenance as required.

4. Remove the grounding device

Grounding the system via Earthing Stud If using the Earthing Stud Grounding Option (N94), use a three-pole grounding harness for fixed ball points to ground the system.

NoteOrdering a grounding harness

To order the grounding harness, contact the Siemens Service Center.

NoteNumber of grounding harnesses

Depending on the configuration of the drive, use a sufficient number of grounding harnesses. A grounding harness is needed for each three-phase system.

Perform the steps as indicated below:

Refer to the diagram Attaching the Grounding Spider.

Figure 10-3 Attaching the grounding spider

1. Secure the terminal of the grounding harness to the lower fixed sphere.②2. Secure the terminals of the grounding harness to the upper fixed spheres.①



10.6.3 Part Replacement

WARNING

Siemens Recommendation of Qualified Personnel Only

Siemens strongly recommends that only qualified personnel be allowed to perform maintenance and replacements on SINAMICS PERFECT HARMONY drives.

Failure to comply with recommendations:● will invalidate any warranty claims should the drive not perform as designed or parts

become damaged● may result in serious injury to personnel, which will be the sole responsibility of the

customer

Refer to the chapter of this manual titled Spare Parts for a listing of parts that are customer replaceable and non-replaceable.

Note

Failures traced to individual power cells require replacement of the entire cell.

10.6.4 Replacing the Filter Media

Filter Media

WARNING

Siemens Recommendation of Qualified Personnel Only


Failure to comply with recommendations:● will invalidate any warranty claims should the drive not perform as designed or parts


customer

Convection-cooled drives are equipped with filter media that prevent dust deposits from accumulating on the power unit components.

Refer to the chapter titled "VFD Power Down and Door Access" prior to replacing the filter media. Filter media cannot be replaced during VFD operation.

Filter Media Replacement Following photographs depict the procedure for replacing a filter.



Figure 10-4 Installed Filter

The first photograph shows a filter as installed on the cabinet enclosure.

Figure 10-5 Screwdriver Insertion Points

Insert a screwdriver into the slots provided (insertion points) at the top of the filter cover. Take care not to scratch the paint.



Figure 10-6 Filter Cover Removal

Remove the filter cover by pulling it forward and outward.

Figure 10-7 Filter with Cover Removed

The image above shows the filter media that is underneath the cover.



Figure 10-8 Filter Removal

To remove the filter media, simply pull it away from the frame.

Replacing Filter Media● After replacing the filter media, carefully place and align the filter cover to the filter frame that

is attached to the VFD.

● Gently push the filter cover onto the frame to latch it in place.

Cleaning the Filter ● Depending on the type of contamination, shake the dust from the filter, vacuum clean them

or wash them. If the filter is highly contaminated, dispose of it properly, and replace the filter.

NoteDo not use pressurized equipment to clean the filters in the door!

The filter mats are made of polyester fiber and must not be cleaned using pressurized equipment (e.g. with water jet or compressed air), since this can damage the filter mats and render them useless.



10.6.5 Replacing the Door-Mounted KeypadTo replace the door-mounted keypad:

1. Switch off the main circuit breaker.

2. Open the cabinet.

3. Disconnect the power and communications connection and the 9-pin connector from the keypad.

4. Unscrew the seven mounting screws.

5. Pull the keypad out to the front.

6. Fit a new keypad.

7. Screw in the seven mounting screws.

8. Reconnect the power and communications connection and the 9-pin connector from the keypad.

10.6.6 Removing the Power Cell ProcedurePower Cell Removal

● Refer to the "VFD Power Down and Door Access" chapter, section "Unlocking the Doors", prior to removing power cells. Be sure to obey all standard electrical and safety instructions.

DANGER

Lethal Voltages

Even when the system is powered down, power may still be present at the power cell's DC bus. The recommended waiting time before opening the doors or removing covers is 10 minutes.

DANGER

Lethal Voltages

The cell should not be touched, removed, or serviced if the indicator is illuminated.The cell chassis is not grounded and when energized can float to lethal voltages. Failure to install proper grounding connections may result in death or cause damage to the drive.

● Use appropriate Personal Protective Equipment (PPE). Be sure not to touch any bare bus bars while removing the power cell.

CAUTION

Existing Voltage May Still Be Present

An LED that is not extinguished indicates that power is present.

The power cells include discharge resistors to dissipate stored energy after the input voltage is removed. The power cell DC bus voltage decays to less than 50 VDC in less than 10 minutes.



● Remove the fiber optic from the Cell Control Board (CCB) as follows:

Figure 10-9 Fiber Optic Removal

Note

Refer to the figure entitled "Fiber Optic Connector Location".

● Be sure to wear proper Personal Protective Equipment (PPE).

● Use the Siemens cell lifter to remove cell from System.

● Disconnect all system bus and cables from the front of the cell. This includes T1,T2 L1, L2, and L3 connections. When bypass option is applicable, the T1 and T2 output bolted connections are made on the bypass contactor.

● Disconnect the power cell from mounting rails (one bolt on each side of cell).

● For 40, 70, 100, and 140 A cells, grab the two handles and pull the cell approximately 1/4 of the way out letting the cell slide on the cell rails as shown in the top figure. Using the Siemens cell lifter (A5E42879582), slide the cell completely out of its slot and onto the lifer.



● For 200 and 260 A cells, grab the cell by the center handle and pull the cell approximately 1/4 of the way out letting the cell slide on the cell rails. Using the Siemens cell lifter, slide the cell completely out of its slot and onto the lifter (A5E42879583).

NoteDo Not Use Standard Cell Lifters with Option Code M58

When option code M58 is selected, standard cell lifters cannot be used.

The lifter for 100-140 cells with M58 option is part number A5E45134411.

WARNING

Proper Handling of Cell when Removing Fiber Optic

DO NOT LIFT UP OR PULL DOWN ON THE CELL when pulling the cell one-fourth of the way out. Ignoring this warning may cause damage to the cell which in turn may cause the System to not function as intended.

● Failures traced to individual power cells require replacement of the entire cell.

● Refer to the chapter of this manual entitled "Disposal and Recycling" to dispose of or recycle failed components.



10.6.7 Replacing the Compact Flash Card (NXGpro)Refer to the following figure when replacing the Compact Flash card.

1 Compact Flash card insertion slotFigure 10-10 NXGpro Digital Control Rack - Compact Flash

Perform the following steps to replace the Compact Flash card.

1. Remove the Compact Flash card from the compact flash slot located on the NXGpro digital control rack.

2. Copy the stored data of the old card to the new original Siemens card.

3. Place the new card into the compact flash slot on the DCR.



10.6.8 Installing Perfect Harmony Power Cells

To Install the Power Cell: 1. Be sure to use proper PPE.

2. Using the Siemens cell lifter, line up the power cell with its slot.

3. Push the cell into its slot. Do not lift up on the cell, but instead let it slide in on the power cell mounting rails.



4. Ensure that the cell chassis mounting edges are sitting inside the edge of the groove rails, and align the cell mounting holes (one on each side), with the corresponding rail receiver holes, as shown in the Figure "Proper alignment of power cell mounting with receiving holes".

Figure 10-11 40 A - 140 A - proper alignment of power cell mounting with receiving holes

Figure 10-12 200 A - 260 A - proper alignment of power cell mounting with receiving holes



NoteProperly Remove and Install 200 A - 260 A Power Cells

When removing and/or installing 200 A - 260 A power cells, be sure to use the handle provided as shown in figure "200 A - 260 A - proper alignment of power cell mounting with receiving holes".Do NOT remove or install the power cells by pulling or pushing on the fuses and bypass contactors that are located on the front panel of power cells.



5. Reinstall the Fiber Optic.

Figure 10-13 Fiber Optic Location

Note

Refer to the figure entitled Fiber Optic Connector Location.

6. Connect the cables to the L1, L2 and L3 input terminals of the power cell by means of bolted connections.

7. Connect the cables to the T1 and T2 output terminals of the power cell by means of bolted connections.



8. Optional: When bypass option is applicable, the T1 and T2 output bolted connections are made on the bypass contactor.

9. Torque connections and their respective DC bus voltage indicators as shown below:

Figure 10-14 40 - 70 A Fiber Optic and DC Bus Indicator

Figure 10-15 Torque Connections for 40 - 70 A Power Cells









WARNING


Failure to comply with recommendation:● will invalidate any warranty claims should the drive not perform as designed or parts


customer

10.6.9 Fuse Location

Fuse LocationThe secondary fuses are located on the front panel of the power cells as shown in Figure "Fuse Location". The location is circled as below.

Figure 10-20 Fuse Location

10.6.10 Replacing Cell Input Power FusesA label is located on the top of the power cell chassis cover that shows all approved replacements. Only two phases of each transformer secondary (power cell input) are fused.

The fuses, located on the front panel, are mounted external to the cell. This not only reduces the size of the cell, but also allows for the fuses to be located in an accessible location. They



primarily provide secondary short circuit protection and are sized to accommodate power cell charging currents upon initial energizing.

NoteMatching Fuses

A mixture of fuse vendors is permitted, but not within the same power cell (i.e., FA1A and FA1C should be from the same vendor).

NoteRecommended Time Limit for Fuse Replacement

As a preventive maintenance measure for drives that experience daily inrush events, Siemens recommends replacing all power fuses that have been in operation for five years.

NotePrimary and E-Rated Fuses

The core drive does not include primary fuses. When E-rated fuses are required, contact Siemens Engineering.

10.6.11 Cell Input Power Fuse Replacement Procedure

Cell Input Power Fuse Replacement Procedure

To replace an open Cell Input fuse:1. Power down the SINAMICS PERFECT HARMONY GH180 system, obeying all standard

electrical and safety instructions. Prior to opening the doors of the VFD, be sure to read the chapter titled "VFD Power Down and Door Access" located in this manual.

2. Open the doors to access the Cell Input Fuse section.

Note

This section varies based on the drive output voltage and cell size. The customer specific documentation shall be referenced to locate the Cell Input Fuse.

3. Use an appropriately sized AC voltage detector to ensure that the power is removed.

WARNING

Electrical Hazard

The secondary rating of a SINAMICS PERFECT HARMONY GH180 transformer to the input of the cell power fuse is 750 VAC or 450 VAC. Qualified personnel must obey all safety precautions. Risk of death, serious personal injury, and equipment damage can occur.



4. Use the appropriate tools to remove the bolts holding the power cable to the fuse mounting feet.

Note

40, 70, 100, 140, 200, & 260 A cells will have an M8 bolt.

5. Remove the open fuse and replace with a spare Cell Input Power Fuse.

6. Re-apply the power cable connections and apply a new torque mark to the bolt.

Note

Torque the M8 bolt connections to 70 IN-LB (7.9 N-M).

10.6.12 Printed Circuit Board Replacement Procedure (NXGpro)Use "Replacing the Printed Circuit Board Procedure" to replace:

● System Interface Board

● User I/O Board

Replacing the Printed Circuit Board Procedure 1. Power down the system, following the standard shut-down procedure.

2. Power down all low voltage feeds to the drive.

Note

Low voltage feeds vary per customer design. The customer specific documentation shall be referenced to identify all low voltage feeds.

3. Use an appropriately sized AC voltage detector to ensure all power is removed to the control.

Note

The drive can accommodate up to a 240 VAC power for the control.



4. Prior to servicing any printed circuit board (PCB), ensure proper ESD protection is followed.

– All circuit boards shipped by Siemens are done so in an ESD protective bag. They must stay inside this bag during transport and storage. They can only be removed after placing the bag on a dissipative ESD workbench surface.

– Before removal from the ESD protective bag, the personnel handling the PCB must be properly grounded. Proper grounding is accomplished by using a heel-grounder on a dissipative floor surface or a wrist strap connected to a proper ground.

Note

ESD sensitive components can be identified by symbols being present on the component or the component packaging.

5. The System Interface Board and the User I/O Board are din-rail mounted within the respective control tub.

Note

The customer specific documentation shall be referenced to identify the location of the System Interface Board or the User I/O Board.

Identify which board requires service and disconnect all connections to that specific board.The board may include 50-pin connectors, ribbon cables, a wire harness, and single control wire connections.

Note

All control wire terminations require a flat-head screwdriver for removal.

6. Use a flat-head screwdriver to depress the two tabs on the board for removal of the PCB from the din-rail.

7. Install the spare PCB on the din-rail.

8. Replace all of the removed connectors, ribbon cables, and wire harnesses.

9. Place the removed PCB into the empty ESD protective bag if the PCB is being returned to Siemens for analysis.





Spare Parts 1111.1 Replaceable Spare Parts

Serviceable PartsThe customer serviceable spares are listed below. For additional information about how to service these parts, refer to the chapter of this manual titled Maintenance.

● Door Filters

● Power Cells

● Cell Input Fuses

● Control Breakers (includes Blower Breakers)

● Fiber-Optic connections

Non Customer Serviceable PartsAll other spare parts are NOT customer serviceable. However, they may be serviced by qualified Siemens personnel. These include, but are not limited to the following:

● Blower(s)

● Bypass Contactor(s)

● Bypass Control Board

● Bypass Power Supply

● Input Current Transformers

● Input/Output Voltage Attenuators

● Hall Effect Current Transducers

● NXGpro Power Supply

● Control Power Supply

● Pre-charge Circuit Breaker

● V20 (VFD)

● Pre-charge Reactor

● Pre-charge Contactor

NoteRefer to Specific System Schematics

Refer to the system outline and system schematic drawings, series A and B respectively for your specific drive. These drawings are contained in the O&M package supplied with the drive.


NoteCustomer Documentation Package● For spare parts lists, refer to the custom documentation package shipped with the drive or

call Siemens Large Drives Customer Service Department. Refer to the appendix Service and Support for contact information.

● When calling for spare part information, please have your sales order number and drive part number readily available.

NoteComponent Replacement

Unless notified differently by Siemens, always replace components with the same P/N and revision level. Failure to comply with the above may cause the drive to function in an undesired and unexpected manner.

Spare Parts11.1 Replaceable Spare Parts


Disposal and Recycling 1212.1 Disposing of Device Components

Before dismantling the drive, ensure that it is de-energized. Refer to the chapter "VFD Power Down and Door Access" prior to disposing of and recycling the components as listed in the following paragraph.

When disposed of properly, none of the hazardous waste in the drive components will pose any threat to the environment. The identification and classification of the hazardous waste may vary in different regions/countries. Refer to applicable local/national hazardous waste directory or consult local authorities concerned prior to disposing of or recycling the drive components. Take particular care when disposing of and recycling the following components:

● Batteries

● Capacitors

● Printed Circuit Board Assemblies (PCBAs)

● Electronic components

● Insulation components

Be sure to employ authorized organizations to dispose of or recycle the hazardous waste in accordance with the applicable local guidelines/regulations and with the applicable national regulations.


Disposal and Recycling12.1 Disposing of Device Components


Service and Support AA.1 Field Service Operation

Siemens can provide trained and certified field service representatives to provide technical guidance and assistance for the installation, startup/commissioning, repair and maintenance of Siemens SINAMICS PERFECT HARMONY GH180 VFD equipment and systems. Contact your regional service call center or sales office for details.

For all regional information, use the following link: www.siemens.com/yourcontact

Siemens service call centers can be reached at the regional locations listed below.

DANGER

Untrained personnel performing work on equipment may cause personal injury, death, equipment damage, VFD operational integrity

Ensure that only personnel trained by Siemens work on the equipment.

Certain components described in this documentation may be replaced or repaired only by personnel trained by Siemens.

Work incorrectly performed on the drive can result in damage to the equipment, degrade VFD operational integrity, and possibly cause physical injury to personnel or even death.

Siemens accepts no liability for any damage that occurs because these instructions have not been observed, e.g. if an untrained person carries out a repair or replaces components.

Technical Support (Hotline) ● For emergency service or technical support please call +86 021 58585775

● America time zone:

Johnson City, TN, USA +1 800 333 7421 +1 423 262 5710

● Asia and Australia time zone:

Beijing/Shanghai, China +86 400 810 4288 +86 021 58585775

● Europe and Africa time zone:

Nuremberg, Germany +49 911 895 7222 +49 180 5050 222

Technical Support (Internet)Send your inquiries directly via the internet to a specialist in technical support:

https://support.industry.siemens.com/cs/sc?lc=en-WW


https://www.industry.usa.siemens.com/drives/us/en/electric-drives/Pages/electric-drives.aspx

● Technical support is available round the clock 24 hours/365 days a year.

● Your inquiries are delivered directly to the responsible specialist.

● Have all relevant data available and technical support can respond to your inquiry as quickly as possible.

● Send records, screen shots and photos to the specialists to support fault analysis.

Service and SupportA.1 Field Service Operation


Technical Data BB.1 Storage, Transport and Operation Ambient Conditions

Table B-1 General Ambient Conditions

Storage Transport OperatingCLIMATIC AMBIENT CONDITIONS

Ambient temperature +5 °C to +40 °C –25 °C to +60 °C

+5 °C to +40 °C (without output current de-rating)+41 °C to +50 °C (with output cur‐rent de-rating)

Relative air humidity < 95% (VFD must be completely dry before commissioning, no condensation)

Other climatic conditions 1K21, 1Z2in accordance with IEC 60721-3-1: 2018

2K12in accordance withIEC 60721-3-2: 2018

3K3in accordance with IEC 60721-3-3: 2002

Degree of pollution 2 without conductive or statically charged semi-conductive pollution in accordance with

IEC 61800-5-1: 2007MECHANICAL CONDITIONS*

References 1M12in accordance with IEC 60721-3-1: 2018

2M4in accordance with IEC 60721-3-2: 2018

Sine Vibration (IEC 61800-5-1: 2007)

Sine Vibration Displace‐ment

No ±0.075 mm (5 to 57 Hz)1 g (57 to 150 Hz)

Random Vibration Curve 1.0 m2/s3 (10 Hz to 100 Hz)-3.0 dB/octave.Hz (100 Hz to 200 Hz)

0.5 m2/s3 (200 Hz to 2000 Hz)No

Steady State Acceleration 2 g XYZ (IEC 60721-4-2: 2003 2M1) NoStacking No stacking permittedFreefall No

OTHER AMBIENT CONDITIONSBiological ambient condi‐tions

1B1 in accordance withIEC 60721-3-1: 2018

2B1in accordance with IEC 60721-3-2: 2018

3B1 in accordance withIEC 60721-3-3: 2002


Storage Transport OperatingMechanical active sub‐stances

1S10 in accordance with IEC 60721-3-1: 2018

2S1in accordance with IEC 60721-3-2: 2018

3S1in accordance with IEC 60721-3-3: 2002with the addition of sand content of 0.01 mg/m3

However, conductive dust not permitted

Chemical conditions 1C2 in accordance with IEC 60721-3-1: 2018However, salt mist is not permitted

2C2 in accordance with IEC 60721-3-2: 2018However, salt mist is not permit‐ted

3C2 in accordance with IEC 60721-3-3: 2002However, salt mist is not permit‐ted

* The chart contains vibration and shock values based on short term, accelerated life testing. These values are not continuous levels for the life of the product. Please reference the appropriate standards for guidelines for specific customer applications.

Technical DataB.1 Storage, Transport and Operation Ambient Conditions


B.2 Power Cell Specifications Table

Cell Type 40 70 100 140 200 260Output Cur‐rent Rating (lo)

No Overload 45 A 76 A 105 A 140 A 210 A 280 A110% Overload1 minute /10 mi‐nutes (CL-1)

45 A 76 A 100 A 140 A 200 A 260 A

Input Voltage 750 V ± 10%, 3-phase, 50/60 HzInput Current 31 A 53 A 73 A 96 A 140 A 182 ACell Efficiency 98.6% 98.8% 98.9% 99% 98.8% 98.8%Power Cell Height 8.25 in

209.5 mm9.25 in235 mm

9.75 in247.6 mm

Power Cell Width 13.00 in330.2 mm

13.00 in330.2 mm

13.60 in345.4 mm

Power Cell Depth 19.99 in 482.4 mm

21.39 in543.3 mm

29.80 in 756.9 mm

Power Cell Weight 40.6 lb18.4 kg

45.9 lb20.8 kg

51.2 lb23.2 kg

55.2 lb25 kg

66.2 lb756.9 mm

66.2 lb30 kg

Electrical Connections Bolted ConnectionStorage Temperature 41 °F (5 °C) to 104 °F (40 °C)Forced Air Cooling > 100 CFM

(100 - 120 CFM typical)> 180 CFM(225 - 250 CFM typical)

> 250 CFM(300 - 320 CFM typical)

Note

The general ambient conditions shown in Table B-1 are applicable to spare parts.

Technical DataB.2 Power Cell Specifications Table


B.3 21/24-Cell Specifications

Cells in Drive(without Reduncancy)

Output VoltageAvailable L-L (with O-M)

KVA Range Power Cell Types

21, 24 10 kV/11 kV 250 - 5250 40, 70, 100, 140, 200, 260

Parameters RatingsInput Line Voltage 3.3 - 13.8 kV;

3-phase; +10%/-10%Input Frequency 50 or 60 Hz ± 5%Input Power Factor ≥ 0.96 fundamental and ≥ 0.95 above 10% loadInput Harmonics Meet IEEE519 (at full output current) requirements at the drive MV input terminals and under

the assumption of full balanced incoming voltages and pre-existing voltage distortion < 2%. A short circuit ratio < 20 with the VFD operating at nominal speed and rated power is as‐sumed.

Inverter Efficiency ≥ 98.5% Output Voltage 21/24 Cells

10 kV/11 kV Output HVF < 0.03Output dv/dt < 3000 V/µSOverload Capacity 110% 1 minute/10 minutes Output Frequency 0.5 Hz ~ 330 Hz

(0.5 Hz ~ 110 Hz for 21-Cell system)Output Torque 10 ~ 167 Hz (2 - Quadrant)

(10 ~ 110 Hz for 21-Cell system)Auxiliary Voltage 380 V 3AC, 50/60 Hz ± 10% continuous operationEnclosure Type VentilatedDegree of Protection Standard: IP31 (Not including blower cage)

Optional: IP42 (Not including blower cage)Ambient Temperature 5 - 40 °C (maximum 50 °C, derating starts from 40 °C on)Altitude Altitude up to 1000 m (3300 ft) – Standard with no output power de-rating.

Altitude above 1000 m (3300 ft) to 2000 m (6600 ft) – Standard output current de-rating.Altitude above 2000 m (6600 ft) to 4500 m (14850 ft) – De-rating

Cooling Ventilated, forced air-cooled with integrated fans

Technical DataB.3 21/24-Cell Specifications


B.4 15-Cell Specifications

Cells in Drive(without Reduncancy)

Output VoltageAvailable L-L (with O-M)

KVA Range Power Cell Types

15 6 kV/6.3 kV/6.6 kV 200 - 3250 40, 70, 100, 140, 200, 260

Parameters RatingsInput Line Voltage 3.3 - 13.8 kV

3 phases; +10%/-10%Input Frequency 50 or 60 Hz ± 5%Input Power Factor ≥ 0.96 fundamental and ≥ 0.95 above 10% loadInput Harmonics Meet IEEE519 (at full output current) requirements at the drive MV input terminals and under

the assumption of full balanced incoming voltages and pre-existing voltage distortion < 2%. A short circuit ratio < 20 with the VFD operating at nominal speed and rated power is as‐sumed.

Inverter Efficiency ≥ 98.5% Output Voltage 15 Cells

6 kV/6.3 kV/6.6 kVOutput HVF < 0.03Output dv/dt < 3000 V/µSOverload Capacity 110% 1 minute/10 minutes Output Frequency 0.5 Hz ~ 330 Hz Output Torque 10 ~ 167 Hz (2 - Quadrant)Auxiliary Voltage 380 V 3 AC, 50/60 Hz ± 10% continuous operationEnclosure Type VentilatedDegree of Protection Standard: IP31 (Not including blower cage)

Optional: IP42 (Not including blower cage)Ambient Temperature 5 - 40 °C (maximum 50 °C, derating starts from 40 °C on)Altitude Altitude up to 1000 m without deratingCooling Ventilated, forced air-cooled with integrated fans

Technical DataB.4 15-Cell Specifications


Technical DataB.4 15-Cell Specifications


Quality CC.1 CE Marking and Directives

The CE marking identifies products that are in compliance with the appropriate EU directives. The CE marking is not a seal of quality. It was created to guarantee end users safe products in the free flow of goods within the European Economic Community (EEC) and the European Community (EC). By applying the CE marking the manufacturer acknowledges the product is in conformance with the applicable EU Directives and the product complies with the “essential requirements” defined in these directives. Based on the Gambica CE Marking and Technical Standardization Guidelines, Edition 3.0, compliance to EN 61800-5-1 is a harmonized standard and confers a presumption of conformity with the essentials of the Low Voltage Directive (LVD).


C.2 CE MarkingApplying the CE marking confers the presumption of conformity to the EU directive(s).

The CE marking is required for all products which fall in the scope of a European Directive (which foresees the CE marking for those products) which are placed on the market in the European Economic Area.

Figure C-1 CE Marking

Note

Access "CE Marking and Technical Standardization - Guidelines for Application to Electrical Power Drive Systems", Edition 3.0, at http://www.gambica.org.uk/

Access EU Directives and Norms at the following link: https://ec.europa.eu/commission/index_en

This site provides access to all European Directives and the appropriate standards according to each manufacturer’s specific products.

QualityC.2 CE Marking


C.3 CE Marking on Power Drive Systems (PDS)The terminology used throughout IEC and EN standards relating to electrical VFDs is contained in the IEC 61800 series of standards. The IEC 61800 series of standards references other components of the PDS with respect to the VFD; however, those components are covered by different IEC product relevant materials.

As referenced in the figure entitled Power Drive System, the installation, parts of the installation, the motor or any machinery, including gearboxes and the driven equipment, are outside of the scope of Siemens' responsibility.

Figure C-2 Power Drive System

Siemens SINAMICS PERFECT HARMONY GH180 designs always include the Basic Drive Module (BDM) that includes a SINAMICS PERFECT HARMONY transformer, converter/inverter (power cell) section, and control section. Depending on the Siemens scope of supply, SINAMICS PERFECT HARMONY GH180 Complete Drive Module (CDM) may include

QualityC.3 CE Marking on Power Drive Systems (PDS)


optional components, such as a motor excitation unit, output line filter, output line reactor, or earthing switches.

Note

As referenced in figure Power Drive System, the installation, parts of the installation, the motor, or any machinery, including gearboxes and the driven equipment, are outside of the scope of Siemens' responsibility.

Figure C-3 Drive System Schematic (Reference: IEC Std 61800-5-1-2007) Drive System Schematic

QualityC.3 CE Marking on Power Drive Systems (PDS)


List of abbreviations DD.1 Abbreviations

This appendix contains a list of symbols and abbreviations commonly used throughout this manual group.

Table D-1 Commonly Used Abbreviations

Abbreviation Meaning• Boolean AND function+ Addition or Boolean OR function∑ Summationµ MicrosecondA Amp, AmpereAC Alternating Currentaccel AccelerationA/D Analog-to-digital (converter)AI Analog InputAlg AnalogAP Advanced protocol for cell communicationavail AvailableBTU British thermal unitsC Centigrade or Capacitorcap CapacitorCCB Cell Control Boardccw Counter clockwiseCE Formerly European Conformity, now true definitionCFM Cubic Feet per MinuteCLVC Closed Loop Vector Controlcmd Commandcom Commonconn ConnectorCPS Control Power SupplyCPU Central Processing UnitCSMC Closed Loop Synchronous Motor ControlCT Current Transformercu Cubiccurr, I Currentcw ClockwiseD Derivative (PID), depthD/A Digital-to-analog (converter)


Abbreviation Meaningdb DecibelDC Direct CurrentDCR Digital Control RackDCS Distributed Control Systemdecel Decelerationdeg, ° DegreesDiv Divisiondmd Demande ErrorELV Extra Low VoltageEMC Electromagnetic CompatibilityEMF Electromotive ForceEMI Electromagnetic InterferenceEPS Encoder Power SupplyESD Electrostatic DischargeESP Electrical Submersible PumpESTOP, e-stop Emergency Stopfb, fdbk Feedbackffwd Feed ForwardFLC Full Load Currentfreq Frequencyft, ' Feetfwd Forwardgnd GroundGUI Graphical User InterfaceH Heighthex Hexadecimalhist HistoricHp Horsepowerhr HourHVAC Heating, Ventilation, Air ConditioningHVF Harmonic Voltage FactorHz HertzI Integral (PID)ID IdentificationIEC International Electrotechnical CommissionIEEE Institute of Electrical and Electronic EngineersIGBT Insulated Gate Bipolar TransistorIn InputIn, " InchesINH InhibitI/O Input(s)/Output(s)IOC Instantaneous Overcurrent

List of abbreviationsD.1 Abbreviations


Abbreviation MeaningIP Input Protectionk 1,000 (e.g., Kohm)kHz KiloHertzkV Kilo VoltskVA One Thousand Volt AmpskW KilowattL InductorLAN Local Area NetworkLbs Pounds (weight)LCD Liquid Crystal Displayld LoadLED Light-emitting DiodeLFR Latch Fault RelayLOTO Lock-Out-Tag-OutLim LimitLOS Loss Of Signallps Liters Per SecondmA Milliamperesmag Magnetizingmax MaximumMCC Motor Control CenterMg MilligramMin Minimum, Minutemsec Millisecond(S)Msl Mean Sea LevelMV Medium Voltagemvlt Motor VoltageMW MegawattNC Normally ClosedNEMA National Electrical Manufacturer’s AssociationNo Normally OpenNVRAM Non-Volatile Random Access MemoryNXG Next Generation ControlNXGpro Next Generation Control proOLVC Open Loop Vector ControlO-M OvermodulationOOS Out of Saturation (IGBT)overld OverloadP Proportional (PID)Pa Pascalspb Push ButtonPC Personal Computer or Printed CircuitPCB Printed Circuit Board



Abbreviation MeaningPID Proportional Integral DerivativePLC Programmable Logic ControllerPLL Phase Locked Looppot Potentiometerpp Peak-to-peakppm Parts per MillionPPR Pulses per RevolutionPQM Power Quality MeterProToPSTM Process Tolerant Protection StrategyPSDBP Power Spectral Density Break Pointpsi Pounds Per Square Inchpt PointPT Potential TransformerPWM Pulse Width ModulationQ1,Q2,Q3,Q4 Output Transistor Designationsrad RadiansRAM Random Access Memoryref Referencerev Reverse, Revolution(S)RFI Radio Frequency InterferenceRLBK Rollbackrms Root-mean-squaredRPM Revolutions Per MinuteRTD Resistance Temperature DetectorRTU Remote Terminal UnitRX Receive (RS232 Communications)s Second(s)SCR Silicon Controlled Rectifiersec Second(s)ser SerialSIB System Interface BoardSMC Synchronous Motor ControlSOP Sum of Products; System Operating Programspd Speedstab Stabilitystd Standardsw SwitchT1, T2 Output Terminals TI and T2TB Terminal BlockTBD To Be DeterminedTCP/IP Transmission Control Protocol/Internet ProtocolTHD Total Harmonic DistortionTOL Thermal Overload



Abbreviation MeaningTP Test Pointtrq, τ TorqueTX Transmit (RS232 Communications)UPS Uninterruptable Power SupplyV Voltage, VoltsVA Volt-AmperesVAC Volts ACvar VariableVDC Volts DCvel Velocity (speed)VFD Variable Frequency DriveV/Hz Volts per Hertzvlts Voltage(s), VoltsW Width, WattsWAGO Expansion I/O System (brand name)xfmr, xformer Transformer





Glossary

ANDAND is a logical Boolean function whose output is true if all of the inputs are true in SOP notation, AND is represented as "∗" (e.g., C=A∗B), although sometimes it may be omitted between operands with the AND operation being implied (e.g., C=AB).

ASCIIASCII is an acronym for American Standard Code for Information Interchange, a set of 8-bit computer codes used for the representation of text.

Baud rateBaud rate is a measure of the switching speed of a line, representing the number of changes of state of the line per second. The baud rate of the serial port is selected through the Baud Rate parameter in the Communications Menu [9].

BitBit is an acronym for BInary digiT. Typically, bits are used to indicate either a true (1) or false (0) state within the drive’s programming.

Boolean algebraA form of mathematical rules developed by the mathematician George Boole used in the design of digital and logic systems.

Carrier frequencyCarrier frequency is the set switching frequency of the power devices (IGBTs) in the power section of each cell. The carrier frequency is measured in cycles per second (Hz).

Catch a spinning load"Catch a spinning load" is a feature that can be used with high-inertia loads (e.g., fans), in which the drive may attempt to turn on while the motor is already turning. This feature can be enabled via the control menu system.

CLVCAn acronym for Closed Loop Vector Control, one of the control modes in the drive. This is flux vector control for an induction machine (IM), utilizing an encoder for speed feedback.


CMP Refer to the glossary term SOP.

ComparatorA comparator is a device that compares 2 quantities and determines their equality. The comparator submenus allow the programmer to specify two variables to be compared. The results of the custom comparison operations can be used in the system program.

Configuration Updatesee Tool Suite definition.

ConverterThe converter is the component of the drive that changes AC voltage to DC voltage.

Critical speed avoidanceCritical speed avoidance is a feature that allows the operator to program up to 3 mechanical system frequencies that the drive will "skip over" during its operation.

CSMCAn acronym for Closed Loop Synchronous Machine (SM) Control, one of the control modes of the drive. This is a flux vector control for a synchronous machine, utilizing an encoder for speed feedback and providing a field excitation command for use by an external field exciter.

DC linkThe DC link is a large capacitor bank between the converter and inverter section of the drive. The DC link, along with the converter, establishes the voltage source for the inverter.

De Morgan’s TheoremThe duality principal of Boolean algebra used to convert system logic equations into sum-of-products notation.

Debug Toolsee Tool Suite definition.

DownloadingDownloading is a process by which information is transmitted from a remote device (such as a PC) to the drive. The term "downloading" implies the transmission of an entire file of information (e.g., the system program) rather than continued interactive communications between the two

Glossary


devices. The use of a PC for downloading requires special serial communications software to be available on the PC, which may link to the drive via RS232 or through the Host Simulator via an ethernet connection.

DRCTRYDirectory file for system tokens and flags used in the compilation of system programs. It provides a direct lookup table of ASCII names to internal ID numbers. It also identifies whether the flag is a word or bit-field, and also whether it can be used as an input or output only, or can be used for both.

DriveThe term "drive" refers to the power conversion equipment that converts utility power into power for a motor in a controlled manner.

ELVELV is an acronym for extra low voltage, and represents any voltage not exceeding a limit that is generally accepted to be 50 VAC and 120 VDC (ripple free).

EMC EMC is an acronym for electromagnetic compatibility–the ability of equipment to function satisfactorily in its electromagnetic environment without introducing intolerable electromagnetic disturbances to anything in that environment.

ESDESD is an acronym for ElectroStatic Discharge. ESD is an undesirable electrical side effect that occurs when static charges build up on a surface and are discharged to another. When printed circuit boards are involved, impaired operation and component damage are possible side effects due to the static-sensitive nature of the PC board components. These side effects may manifest themselves as intermittent problems or total component failures. It is important to recognize that these effects are cumulative and may not be obvious.

Fault logFault messages are saved to memory so that the operator may view them at a later time. This memory location is called the fault log. The fault log lists both fault and alarm messages, the date and time that they occurred, and the time and date that they are reset.

FaultsFaults are error conditions that have occurred in the system. The severity of faults vary. Likewise, the treatment or corrective action for a fault may vary from changing a parameter value to replacing a hardware component such as a fuse.

Glossary


Flash CardNon-volatile memory storage device for the control. It stores the drive program, system program, logs, parameters, and other related drive files.

FPGAField Programmable Gate Array. An FPGA is an integrated circuit that contains thousands of logic gates.

FunctionA function is one of four components found in the menu system. Functions are built-in programs that perform specific tasks. Examples of functions include System Program Upload/Download and Display System Program Name.

HarmonicsHarmonics are undesirable AC currents or voltages at integer multiples of the fundamental frequency. The fundamental frequency is the lowest frequency in the wave form (generally the repetition frequency). Harmonics are present in any non-sinusoidal wave form and cannot transfer power on average.

Harmonics arise from non-linear loads in which current is not strictly proportional to voltage. Linear loads like resistors, capacitors, and inductors do not produce harmonics. However, non-linear devices such as diodes and silicon controlled rectifiers (SCRs) do generate harmonic currents. Harmonics are also found in uninterruptable power supplies (UPSs), rectifiers, transformers, ballasts, welders, arc furnaces, and personal computers.

Hexadecimal digitsHexadecimal (or "hex") digits are the "numerals" used to represent numbers in the base 16 (hex) number system. Unlike the more familiar decimal system, which uses the numerals 0 through 9 to make numbers in powers of 10, the base 16 number system uses the numerals 0, 1, 2, 3, 4, 5, 6, 7, 8, 9, A, B, C, D, E, and F to make numbers in powers of 16.

Historic logThe historic log is a troubleshooting/diagnostic tool of the control. The historic log continuously logs drive status, including the drive state, internal fault words, and multiple user-selectable variables. This information is sampled every slow loop cycle of the control (typically 450 to 900 times per second). If a fault occurs, the log is frozen a predefined number of samples after the fault event, and data samples prior to and after the fault condition are recorded to allow post-fault analysis. The number of samples recorded are user-selectable via the control, as well as the option to record the historic log within the VFD event log.

Host Simulatorsee Tool Suite definition.

Glossary


I/OI/O is an acronym for input/output. I/O refers to any and all inputs and outputs connected to a computer system. Both inputs and outputs can be classified as analog (e.g., input power, drive output, meter outputs, etc.) or digital (e.g., contact closures or switch inputs, relay outputs, etc.).

IGBTIGBT is an acronym for Insulated Gate Bipolar Transistors. IGBTs are semiconductors that are used in the drive to provide reliable, high-speed switching, high-power capabilities, improved control accuracy, and reduced motor noise.

Induction motorAn induction motor is an AC motor that produces torque by the reaction between a varying magnetic field (generated in the stator) and the current induced in the coils of the rotor.

Intel hexIntel hex refers to a file format in which records consist of ASCII format hexadecimal (base 16) numbers with load address information and error checking embedded.

InverterThe inverter is a portion of the drive that changes DC voltage into AC voltage. The term "inverter" is sometimes used mistakenly to refer to the entire drive (the converter, DC link, and inverter sections).

Jog modeJog mode is an operational mode that uses a pre-programmed jog speed when a digital input (programmed as the jog mode input) is closed.

JumpersJumper blocks are groups of pins that can control functions of the system, based on the state of the jumpers. Jumpers (small, removable connectors) are either installed (on) or not installed (off) to provide a hardware switch.

Ladder logic (Also Ladder Diagram)A graphical representation of logic in which two vertical lines, representing power, flow from the source on the left and the sink on the right, with logic branches running between, resembling rungs of a ladder. Each branch consists of various labeled contacts placed in series and connected to a single relay coil (or function block) on the right.

Glossary


Loss of signal featureThe loss of signal feature is a control scheme that gives the operator the ability to select one of three possible actions in the event that the signal from an external sensor, configured to specify the speed demand, is lost. Under this condition, the operator may program the drive (through the system program) to (1) revert to a fixed, pre-programmed speed, (2) maintain the current speed, or (3) perform a controlled (ramped) stop of the drive. By default, current speed is maintained.

LVDLVD is an acronym for Low Voltage Directive, a safety directive in the EU.

Lvl RHThis term refers the two security fields associated with each parameter of the system. These fields allow the operator to individually customize specific security features for each menu option (submenu, parameter, pick list, and function). These fields are shown in parameter dumps and have the following meanings. Lvl is the term for the security level. Setting R=1 blocks parameter change, and setting H=1 hides the menu option from view until the appropriate access level has been activated.

MemoryMemory is the working storage area for the drive that is a collection of RAM chips.

Microprocessor A microprocessor is a central processing unit (CPU) that exists on a single silicon chip. The microprocessor board is the printed circuit board on which the microprocessor is mounted. The drive employs a single-board computer with a Pentium® microprocessor.

NEMA 1 and NEMA 12NEMA 1 is an enclosure rating in which no openings allow penetration of a 0.25-inch diameter rod. NEMA 1 enclosures are intended for indoor use only. NEMA 12 is a more stringent NEMA rating in which the cabinet is said to be "dust tight" (although it is still not advisable to use NEMA 12 in conductive dust atmospheres). The approximate equivalent IEC rating is IP52.

Normally closed (NC)Normally closed refers to the contact of a relay that is closed when the coil is de-energized.

Normally open (NO)Normally open refers to the contact of a relay that is open when the coil is de-energized.

Glossary


OLTMAn acronym for Open Loop Test Mode, one of the control modes of the drive.

OLVCAn acronym for Open Loop Vector Control, also known as Encoderless Vector Control. OLVC is a flux vector control that is one of the control modes of the drive. The drive computes the rotational speed of the rotor and uses it for speed feedback.

OOSOOS is an abbreviation for out of saturation - a type of fault condition in which a voltage drop is detected across one of the IGBTs during conduction. This can indicate that the motor is drawing current too rapidly or in excess.

OROR is a logical Boolean function whose output is true if any of the inputs is true. In SOP notation, OR is represented as "+".

ParameterA parameter is one of four items found in the menu system. Parameters are system attributes that have corresponding values that can be monitored or, in some cases, changed by the user.

PED PED is an acronym for pressure equipment directive, a directive of the EU relating to pressure vessels.

Pick listA pick list is one of four items found in the menu system. Pick lists are parameters that have a finite list of pre-defined "values" from which to choose, rather than a value range used by parameters.

PIDPID is an acronym for proportional + integral + derivative, a control scheme used to control modulating equipment in such a way that the control output is based on (1) a proportional amount of the error between the desired setpoint and the actual feedback value, (2) the summation of this error over time, and (3) the change in error over time. Output contributions from each of these three components are combined to create a single output response. The amount of contribution from each component is programmable through gain parameters. By optimizing these gain parameters, the operator can "tune" the PID control loop for maximum efficiency, minimal overshoot, quick response time, and minimal cycling.

Glossary


Qualified userA qualified user is a properly trained individual who is familiar with the construction and operation of the equipment and the hazards involved.

RAMRAM is an acronym for Random Access Memory, a temporary storage area for drive information. The information in RAM is lost when power is no longer supplied to it. Therefore, it is referred to as volatile memory.

RegenerationRegeneration is the characteristic of an AC motor to act as a generator when the rotor’s mechanical frequency is greater than the applied electrical frequency.

RelayA relay is an electrically controlled device that causes electrical contacts to change their status. Open contacts will close and closed contacts will open when rated voltage is applied to the coil of a relay.

RS232CRS232C is a serial communications standard of the Electronics Industries Association (EIA).

Set pointSet point is the desired or optimal speed of the VFD to maintain process levels (speed command).

SlipSlip is the difference between the stator electrical frequency of the motor and the rotor mechanical frequency of the motor, normalized to the stator frequency as shown in the following equation:

Slip = (ωS - ωR) / ωS

Slip compensationSlip compensation is a method of increasing the speed reference to the speed regulator circuit (based on the motor torque) to maintain motor speed as the load on the motor changes. The slip compensation circuit increases the frequency at which the inverter section is controlled to compensate for decreased speed due to load droop. For example, a motor with a full load speed of 1760 rpm has a slip of 40 rpm. The no load rpm would be 1800 rpm. If the motor nameplate current is 100 A, the drive is sending a 60 Hz wave form to the motor (fully loaded); then the slip compensation circuit would cause the inverter to run 1.33 Hz faster to allow the motor to operate at 1800 rpm, which is the synchronous speed of the motor.

Glossary


SMCIs an acronym for Synchronous Motor Control, one of the control modes of the drive. This mode computes the rotational speed similarly to open-loop vector control, and controls the field reference or the synchronous motor as in closed-loop synchronous motor control.

SOP(1) SOP is an acronym for Sum Of Products. The term "sum-of-products" comes from the application of Boolean algebraic rules to produce a set of terms or conditions that are grouped in a fashion that represents parallel paths (ORing) of required conditions that all must be met (ANDing). This would be equivalent to branches of connected contacts on a relay logic ladder that connect to a common relay coil. In fact, the notation can be used as a shortcut to describe the ladder logic.

(2) SOP, when used as a filename extension, refers to System Operating Program.

SOP UtilitiesThe program within the Siemens Tool suite used for converting between text and machine loadable code. It can also be used for uploading and downloading files over the RS232 connection.

See Tool Suite definition.

Speed Menu functionSpeed menu is a feature of the menu system that allows the operator to directly access any of the menus or parameters, rather than scrolling through menus to the appropriate item. This feature uses the [Shift] button in conjunction with the right arrow. The user is prompted to enter the four digit ID number associated with the desired menu or parameter.

Stop modeStop mode is used to shut down the drive in a controlled manner, regardless of its current state.

SubmenusA submenu is one of four components found in the menu system. Submenus are nested menus (i.e., menus within other menus). Submenus are used to logically group menu items based on similar functionality or use.

Synchronous speedSynchronous speed refers to the speed of an AC induction motor’s rotating magnetic field. It is determined by the frequency applied to the stator and the number of magnetic poles present in each phase of the stator windings. Synchronous Speed equals 120 times the applied Frequency (in Hz) divided by the number of poles per phase.

Glossary


System Operating ProgramThe functions of the programmable inputs and outputs are determined by the default system program. These functions can be changed by modifying the appropriate setup menus from the front keypad and display. I/O assignments can also be changed by editing the system program (an ASCII text file with the extension .SOP), compiling it using the compiler program, and then downloading it to the controller through its serial port, all by utilizing the SOP Utility Program with the Siemens ToolSuite.

Tool SuiteIs the suite of programs developed by Siemens that allows easier access to the drive for programming and monitoring. It is comprised of the following components:

● Tool Suite Launcher - also referred to as Tool Suite; used for coordinating other tools.

● SOP Utilities - used to launch an editor that compiles or reverse compiles a System Program. It also allows for serial connection to the drive for uploading and downloading System Programs.

● Configuration Update - allows for backing-up, updating, and cloning drives via direct access to the Flash Disk.

● Host Simulator - used for monitoring, programming, and controlling a drive remotely from a PC over the built-in ethernet port of the drive. Parameter changes, status display, and graphing of internal variables are its main functions.

● Debug Tool - this tool is used to display the diagnostic screens of the drive for diagnosing drive problems or improving performance via the built-in ethernet port of the drive.

Tool Suite Launchersee Tool Suite definition.

TorqueThe force that produces (or attempts to produce) rotation, as in the case of a motor.

UploadingUploading is a process by which information is transmitted from the drive to a remote device such as a PC. The term uploading implies the transmission of an entire file of information (e.g., the system program) rather than continued interactive communications between the two devices. The use of a PC for uploading requires communications software to be available on the PC.

Variable frequency drive (VFD)A VFD is a device that takes a fixed voltage and fixed frequency AC input source and converts it to a variable voltage, variable frequency output that can control the speed of a motor.

Glossary


VHZIs an acronym for Volts per Hertz control, one of the control modes in the drive. This mode is intended for multiple motors connected in parallel. Therefore, it disables spinning load and fast bypass. This is essentially open-loop vector control with de-tuned (smaller bandwidth obtained by reducing the gain) current regulators.

Glossary


Glossary


Index

Aabbreviations, 123Access plate, 60air transport, 34Anchoring Cabinets, 58Arcing, 16Asynchronous motors, 13Auxiliary power supply, 13

Bbasic drive module, 122

Ccabinet, 31Cabling, 13CE marking, 119, 120

Gambica guidelines, 119Cell Input Power Fuse

matching fuses, fuse replacement, primary fuses, E-rated fuses, 103

center of balance, 31centers of gravity, 36cleaning

contamination, 85Commissioning, 13contact

hotline, 111website, 111

control power, 29Cooling System

components, 29function of, 29

crated items, 36

Ddamage, 52Dimensions, 58drive cabinet, 31Dust deposits, 85

EElectrostatic discharge, 17Electrostatic Protective Measures, 18EMC-compliant installation, 13EU directives, 119, 120

Ffinal placement, 53Five safety rules, 14foundation, 49free fall, 33fuse sources

blown cell input fuse, 102

GGrounding, 13

Hhandling, 36handling requirements, 36

IIndustrial network, 13Input conductor

sizing guidelines, 61Input Protection Scheme, 21inspection, 36, 52, 53Install Perfect Harmony Power Cells, 96Installation, 13installing, 31

JJ bars, 58

Kkeypad

display interface, 27


functions, 26multi-language, 27

Llift capacity located on the longest side of the transportation unit, 31lifting, 36lifting and installing the cabinet, 31Lock-out / Tag-out procedure, 15Low Voltage Directive, 119

MMain entry, 81, 122maximum lift height, 47medium input voltage circuit breaker

Coordinated Input Protection Scheme, 21medium voltage, 29moisture vapor barrier, 33mounting, 53

Oocean and air transport, 34ocean transport, 34of free fall and pitch and roll., 34off-loading, 38, 40

Ppipe rollers, 49pitch roll, 33placement, 55

Rrail transport, 35receiving, 38receiving procedure

damage, 39inspection, 39

reforming, 55replacement of parts,

Compact Flash card, 95residual current device, 71roller dollies, 50

SSecondary Circuit Fault

Coordinated Input Protection Scheme, 21Shielding, 13shipping split, 31shock and vibration, 35Slector Switch

Off-Hand-Auto Selector, 28Standard Scope of Supply

Blowers, 19Control Section, 19Input/Output Section, 19Transformer Section, 19

storage, 36, 53, 55ambient conditions, 55

stretch-wrap, 33symbols, 123Synchronous motors, 13

Ttechnical support

hotline, 111temperature, 53, 55Top angles, 58Torque Specifications, 61touch-up paint, 84Transformer

configuration of, 20Transport, 13

air, truck, water,

transportationpipe rollers, 49roller dollies, 50

transportation unit, 31truck transport, 33truck, trailer, and lorry transport, 34

Uuncrated cabinet, 36unpacking, 52

damage, 52inspection, 52

Index


VVariable-Speed Drives, 13

Wwarranty coverage, 35water transport, 33

Index


Index


Germany

For more information

www.siemens.com/drives

Siemens AGPD LDPostfach 48 4890026 NÜRNBERG

Medium Voltage Variable Frequency Drive

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