Siemens 6SL3825, Operating Instructions Manual

Page 1: ...www siemens com drives Medium Voltage Drive SINAMICS PERFECT HARMONY GH150 Type 6SL3825 Operating Instructions Installation Instructions Edition 05 2020 ...

Page 2: ...19 06 2020 09 58 V14 00 ...

Page 3: ...on Instructions Edition 05 2020 Introduction 1 Safety instructions 2 Description 3 Preparations for use 4 Assembly 5 Electrical connection 6 Commissioning 7 Operation 8 Maintenance 9 Spare parts 10 Disposal 11 Service Support A Technical data and drawings B Quality documents C Additional documents D ...

Page 4: ...re those who based on their training and experience are capable of identifying risks and avoiding potential hazards when working with these products systems Proper use of Siemens products Note the following WARNING Siemens products may only be used for the applications described in the catalog and in the relevant technical documentation If products and components from other manufacturers are used ...

Page 5: ...eaker provided by the customer 22 2 8 Residual risks 23 2 9 Security information 25 3 Description 27 3 1 Area of application 27 3 2 Safety concept 27 3 2 1 Safety components and functions 27 3 2 2 External safety components 28 3 2 3 Protection and monitoring functions of internal components 28 3 2 4 Protection and monitoring functions for external components 28 3 3 Design 29 3 4 Control Module 30 ...

Page 6: ...nstallation location 47 4 2 Inspections when the equipment is received 47 4 2 1 Checking shock and tilt indicators 47 4 2 2 Checking the load handling attachments 48 4 3 Transport 49 4 3 1 Transport markings 49 4 3 2 Transport requirements 49 4 3 3 Observe center of gravity 50 4 3 4 Transport with a fork lift truck 50 4 3 5 Transport with a crane 51 4 3 6 Using lifting rods 51 4 3 7 Transporting t...

Page 7: ...cedure 79 6 8 3 Shield connection 79 6 9 Connecting the re cooling unit to the drive 80 6 10 Interconnecting optional connections 80 6 11 Fastening the cable ducts with cable ties 81 7 Commissioning 83 7 1 Commissioning 83 7 2 Safety instructions for commissioning 83 7 3 STARTER software 84 8 Operation 85 8 1 Safety instructions for operation 85 8 2 Operating the converter 86 8 3 Functions 86 8 3 ...

Page 8: ...ont 98 9 5 1 2 Replacing fans from the back 99 9 6 Cleaning 100 9 6 1 Cleaning aluminum parts 101 9 7 Repair 101 9 7 1 Components that can be replaced 103 9 7 2 Torques 103 9 7 3 Replacing the AVT combination module 105 9 7 4 Replacing the current transformer 106 9 7 5 Replacing the precharging transformer 107 9 7 6 Replacing the precharging rectifier 108 9 7 7 Replacing a power cell 109 9 7 8 Rep...

Page 9: ...e 9 4 Tightening torques for screw terminals for copper cables without cable lug 1 104 Table B 1 Standards and regulations 135 Table B 2 Climatic environmental conditions 136 Table B 3 Mechanical ambient conditions 136 Table B 4 Other ambient conditions 137 Figures Figure 2 1 ESD information 19 Figure 3 1 Example Design of the converter 29 Figure 3 2 Block diagram Basic Line Module with diodes 30 ...

Page 10: ...e of an AVT combination module 105 Figure 9 5 Replacing the current transformer 106 Figure 9 6 Example diagram Replacing the pre charging rectifier 108 Figure 9 7 Removing a power cell steps 1 7 110 Figure 9 8 Removing a power cell steps 8 10 111 Figure 9 9 Removing a power cell step 11 111 Figure 9 10 Removing a power cell step 12 112 Figure 9 11 Example diagram Capacitance of the capacitor bank ...

Page 11: ...Figure 9 24 Remove the operator panel 126 Figure 9 25 Card slots 127 Table of contents SINAMICS PERFECT HARMONY GH150 6SL3825 Operating Instructions 05 2020 11 ...

Page 12: ...Table of contents SINAMICS PERFECT HARMONY GH150 6SL3825 12 Operating Instructions 05 2020 ...

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

Page 14: ...Introduction 1 1 About these instructions SINAMICS PERFECT HARMONY GH150 6SL3825 14 Operating Instructions 05 2020 ...

Page 15: ...mentation may only be operated by personnel qualified for the specific task in accordance with the relevant documentation for the specific task in particular its warning notices and safety instructions Because of their training and experience qualified personnel can recognize any risks involved with handling these products systems and avoid any possible dangers 2 3 The 5 safety rules To ensure you...

Page 16: ... parts can result in death or serious injury Carefully comply with the 5 safety rules Page 15 Operate the device properly Service and maintain the device regularly and correctly Electric shock caused by induced voltage Rotating machinery can induce dangerous high voltages and synchronous motors that are not de excited immediately can also pose a hazard If the connection to the motor is not isolate...

Page 17: ...from the pressure relief flaps Fire can escape through the pressure relief flaps if arcing occurs Persons who are on the roof section of the drive can suffer severe burns Objects that are on the roof section of the drive can catch fire or be flung into the room Death serious injury or material damage can result Never climb on the drive Never place any objects on the roof section of the drive Dange...

Page 18: ...al current monitoring device RCD it is possible that the residual current monitoring device will trip in error nuisance trip The converter may be switched off as a result of the protection device tripping in error To minimize the risk of faulty trips use a type B RCD 2 5 Electromagnetic fields in electrical power engineering installations Electromagnetic fields are generated during operation of el...

Page 19: ...ing made of synthetic fibers Bring components into contact only with ESD compliant materials e g ESD tables ESD surfaces ESD packaging Only carry out measurements on the components if one of the following conditions is met The measuring device is grounded with a protective conductor for example The measuring head of a floating measuring device has been discharged directly before the measurement Th...

Page 20: ...ety and construction regulations and the regulations for using personal protective equipment are observed during all work The operating instructions and the complete product documentation are always available when carrying out any work The technical data as well as the specifications relating to the permissible installation connection ambient and operating conditions are taken into account at all ...

Page 21: ...tor from one of the following variants According to local wiring regulations Calculated according to IEC 60364 5 54 543 1 Half a phase conductor cross section 2 7 3 Installation site safety Danger due to an unsecured installation location This device is used in industrial power installations Improper use incorrect operation insufficient maintenance and access by unauthorized persons can lead to ac...

Page 22: ... reduce electromagnetic fields at their source Make sure that personnel are wearing the appropriate protective gear 2 7 5 Requirements for the circuit breaker provided by the customer The circuit breaker on the primary side of the input transformer on the plant side belongs to the safety system of the drive If a fault occurs inside the drive the energy that is effective at the fault location must ...

Page 23: ...e drive to the circuit breaker must act directly without intervention of coupling relays A feedback signal must be available for each of the circuit breaker states CLOSED and OPEN The feedback signals must not be delayed Do not use any coupling relays An additional independently operating overcurrent protection for the circuit breaker must be provided on the plant side transformer and cable protec...

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

Page 25: ...s 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 constitute one element of such a concept Customers are responsible for preventing unauthorized access to their plants systems machines and networks Such sy...

Page 26: ... cs ww de view 109751848 en Security Guidelines for SIMATIC HMI devices Manual Notes relating to Industrial Security for HMI devices are available here https support industry siemens com cs de en view 109481300 Safety instructions 2 9 Security information SINAMICS PERFECT HARMONY GH150 6SL3825 26 Operating Instructions 05 2020 ...

Page 27: ...ncept guarantees safe installation safe operation as well as safe service and maintenance The safety concept encompasses safety components and functions to protect the device and operators The device is also equipped with monitoring functions to protect external components The device operates safely when the interlock and protection systems are functioning properly Nevertheless there are areas tha...

Page 28: ...er unit Precharging monitoring Supply voltage monitoring Insulation monitoring Monitoring of the common power supply Circuit breaker monitoring Re cooling unit monitoring Shutdown in the event of semiconductor failure Shutdown in the event of control component failure Internal protection functions for the control hardware Protection against communication failure between the closed loop control and...

Page 29: ... Module in M2C technology is optionally available ʪ ʪ Circuit breaker Motor Module M2C Converter transformer Inverter IGBT Basic Line Module Actual value sensing on the motor side Diode rectifier High voltage motor DC link actual value sensing Figure 3 1 Example Design of the converter Description 3 3 Design SINAMICS PERFECT HARMONY GH150 6SL3825 Operating Instructions 05 2020 29 ...

Page 30: ... Depending on the design the Basic Line Module consists of series connected six pulse rectifiers In order to limit the short circuit currents per unit the Basic Line Modules are constructively divided into multiple cabinets RC combinations are provided to protect the diodes Figure 3 2 Block diagram Basic Line Module with diodes Note Details on the design can be found in the layout diagram 3 6 Moto...

Page 31: ...he inverter unit has three phases Each phase comprises two so called M2C branches The six branches of the M2C inverter each consist of identical power cells connected in series The phase of the voltage source DC link drive is realized employing M2C technology using power cells connected in series for two branches Branch identical power cells connected in series Power cell Bypass switch optional Ac...

Page 32: ...ime must not exceed three seconds Provide an overpressure valve in the raw water discharge of the heat exchanger To keep the temperature of the ionized water constant within specified limits and to prevent condensation on request a control valve tree way valve can be installed as bypass Because the valve is controlled depending on the temperature of the deionized water up to approx 100 of the raw ...

Page 33: ...s in the deionized water can cause the cooling system to fail This could damage the drive Use only deionized water that corresponds to the specifications The specification of the deionized water can be found in the documentation for the re cooling unit The level in the deionized water expansion tank and the pump motor circuit breakers are monitored Any water leak is also detected The pressure of t...

Page 34: ... in the ion exchanger with an original filling If the conductivity continues to rise the re cooling unit and drive are switched off The ion exchanger is a consumable and is not covered by the warranty Dirt filters The re cooling unit is equipped with several dirt filters A dirt filter with a sieve mesh width 0 5 mm is located in front of the drive intake A fine filter mesh width 0 05 mm is located...

Page 35: ...0 5 mm pH value 6 5 to 8 0 Carbonate hardness 0 9 mMol l 5 dH Total hardness 1 7 mMol l 9 5 dH Chloride 60 mg l Sulfate 80 mg l Nitrate 10 mg l Core 0 2 mg l Ammonia 10 mg l Dissolved solids 3 4 mMol l 340 ppm Where values deviate from the above stated a water analysis should be carried out in order to ensure the long term stability of the heat exchanger 3 8 Components Further information is avail...

Page 36: ...acts as the physical interface between the power unit and the open loop closed loop controller This is where the galvanic isolation electrical coupling via light between the power unit and the open loop controller takes place Data is exchanged between the Power Stack Adapter and the Control Unit via the DRIVE CLiQ high speed serial communication interface Description 3 8 Components SINAMICS PERFEC...

Page 37: ...2 DRIVE CLiQ interfaces X70 to X81 X170 to X175 Actual value channels X90 to X93 X190 to X193 PSA link X11 to X16 X111 to X116 X21 to X26 X121 to X126 X31 to X36 X131 to X136 X41 to X46 X141 to X146 X51 to X56 X151 to X156 X61 to X66 X161 to X166 Gating of the power semiconductors Figure 3 4 Interface overview of Power Stack Adapter 5 See also DRIVE CLiQ interface Page 46 LEDs of the Power Stack A...

Page 38: ...Replacing a power cell Page 109 3 8 4 1 IGBT module Every IGBT module comprises the following components Cooling plate Two IGBTs Control electronics Discharge resistors A branch reactor is located in each phase between the branch connections and the phase output The IGBTs can limit and disconnect a short circuit current This means that the converter is short circuit proof that is a short circuit w...

Page 39: ...d The capacitor bank is discharged via the gating electronics and discharge resistors 3 8 5 Door limit switch Door limit switches monitor the doors The circuit breaker opens when a door is opened 3 8 6 Electromechanical door interlocking system The electromechanical door interlock system is designed to protect personnel and is an integral part of the safety concept During operation all the doors a...

Page 40: ...dules are separated and isolated from circuits that can be touched using a transformer The AVT combination modules convert analog signals into digital signals They transfer signals to the Power Stack Adapter PSA via fiber optic cables Detailed information about interconnecting the actual value sensing modules is provided in the circuit manual The component mounting locations are provided in the la...

Page 41: ...hat the upstream miniature circuit breaker is opened and after approximately 10 seconds is closed again 3 8 9 2 Connections 8 LED display for the power output Signaling Operating display Line connection Power outputs Figure 3 6 Overview 3 8 9 3 Interface description Tasks of the interfaces Connector Task X1 Line connection X2 Signaling X6 X7 X8 X9 Power output Description 3 8 Components SINAMICS P...

Page 42: ..._A X2 7 Presence of output voltage REL_B X6 1 X7 1 X8 1 X9 1 PE X6 2 X7 2 X8 2 X9 2 P GRD X6 3 X7 3 X8 3 X9 3 55 V 3 8 10 Touch screen operator panel The converter is operated and diagnosed using the operator panel Figure 3 7 Operator panel The operator panel communicates with the drive via Ethernet Description 3 8 Components SINAMICS PERFECT HARMONY GH150 6SL3825 42 Operating Instructions 05 2020...

Page 43: ...ided in the layout diagram 3 8 12 Line filter Line filters are used to suppress interference in the auxiliary power supplies Information about the connection of the line filters is contained in the circuit manual The mounting location is provided in the layout diagram Figure 3 8 Line filter 3 8 13 SIRIUS safety relay The safety relay has failsafe enabling circuits as NO contact circuits The LEDs i...

Page 44: ...loop control Protection and monitoring equipment DC link precharging Cooling unit pumps Refer to the technical data for the auxiliary power supply current rating The terminal assignment is provided in the circuit diagram 3 8 15 Customer terminal strips The signals are allocated to various terminal strips according to voltage level The cables are visually distinguished from one another by various c...

Page 45: ... flows out through the return pipe See also Connecting the water circuits Page 66 3 9 2 Electrical interfaces Auxiliary supply and signals 15 pin interfaces for the auxiliary power supply and signals are available at the input and output Figure 3 9 Auxiliary supply and signal interfaces See also Laying the signal lines Page 76 Description 3 9 Interfaces SINAMICS PERFECT HARMONY GH150 6SL3825 Opera...

Page 46: ...d do not use 5 Reserved do not use 6 RXN Receive data 7 Reserved do not use 8 Reserved do not use A 24 V Power supply B M 0 V Electronics ground Blanking plate for DRIVE CLiQ interface Molex order number 85999 3255 The maximum DRIVE CLiQ cable length is 50 m Description 3 9 Interfaces SINAMICS PERFECT HARMONY GH150 6SL3825 46 Operating Instructions 05 2020 ...

Page 47: ...pair operation For information about permissible ambient and installation conditions see the Technical data and drawings section 4 2 Inspections when the equipment is received 4 2 1 Checking shock and tilt indicators The purpose of shock and tilt indicators The unit is equipped with shock and tilt indicators to monitor for damage during transit Carefully check the shock and tilt indicators before ...

Page 48: ...r possible damage Replace load suspension devices if they are damaged Before use check that the load suspension devices are correctly attached When lifting use only approved and undamaged lifting gear of sufficient rated capacity Check the lifting gear prior to its use WARNING Danger to life as a result of damaged load suspension devices and lifting gear If the load suspension devices and lifting ...

Page 49: ... licenses You must observe the specifications to avoid transport damage to the enclosure and you must maintain the permissible climatic conditions during operation in accordance with IEC 60721 3 1 2 3 Please also observe the Technical specifications instructions For lifting the device always use certified and adequately dimensioned cable guiding and spreading devices that are in absolutely perfect...

Page 50: ...tion work URQW YLHZ 6LGH YLHZ Figure 4 2 Example illustration of centers of gravity 4 3 4 Transport with a fork lift truck WARNING Danger when a transport unit cabinet tips over If the forks are too short this can cause the transport unit cabinet to tip over resulting in death serious injury or damage to the cabinet The forks of the truck must protrude at the rear of the transport pallet The floor...

Page 51: ...ort the equipment keep to the permissible lifting capacity Pay attention to the center of gravity position If the cabinet center of gravity is off center use suitable lifting equipment e g a lifting beam If the cabinet has eye hooks use them In such cases do not use any lifting rods 4 3 6 Using lifting rods When transporting by crane note that the force is applied via the transport rails attached ...

Page 52: ...through the holes Figure 4 3 Lifting bar label 3 Place the sling ropes on the lifting bars so they are close to the cabinet Secure the ends of the lifting bars using the splint Figure 4 4 Securing the lifting rods 4 To lift the transport unit use single sling ropes or two ropes with a cross stitch Attach the crane rope to the lifting rods so it is close to the cabinet 5 Lift the cabinet Avoid shif...

Page 53: ...ces Transportation with the crane WARNING Danger due to falling transport unit cabinet If the lifting gear or load suspension devices were to fail the transportation unit the cabinet could fall Death serious injury or material damage can result Do not stand underneath or near to a raised load To protect the boxes against pressure use sufficiently long rope and a spreader beam Please proceed as fol...

Page 54: ...a crane Page 51 4 3 8 Transporting a re cooling unit Refer to the operating instructions of the re cooling unit for notes relating to transport and storage NOTICE Damage to the ion exchange cartridge as a result of frost If the ion exchange cartridge is exposed to frost it may be damaged Only transport and store the ion exchange cartridge in non frosty conditions More information is available in t...

Page 55: ...n Protect the cabinets against dust until they have been commissioned To do this cover the ventilation openings and keep the doors closed Do not remove the safety instructions and center of gravity specifications from the cabinet 4 4 2 Removing load securing devices WARNING Danger to life as a result of fixing materials under tension If fixing materials are released suddenly during opening and peo...

Page 56: ...tly When opening the doors follow the steps described If the locking mechanism is damaged it is essential that you have it repaired before commissioning the drive system If this is the case then contact the Service Center You can find the relevant contact persons at Service Support The drive is delivered in a closed state A label showing how to open the doors in a current free state is located on ...

Page 57: ...rs can become detached and fall into the device as a result of high temperatures Material or temperature damage may result Remove the shipping indicators before commissioning Remove any adhesive residue from the shipping indicators using methylated spirits See also Checking shock and tilt indicators Page 47 4 5 Storage 4 5 1 Emptying the drive NOTICE Frost damage or corrosion as a result of the co...

Page 58: ...essure If the blow out pressure used exceeds 6 bar the piping and the heat sink can become damaged Do not exceed the blowout pressure of 6 bar Avoid pressure surges 4 5 2 Storing a device If you are not going to commission the device immediately after delivery ensure that it is stored correctly Preconditions and preparations Store goods only in undamaged packaging Unpack the goods if the packaging...

Page 59: ...e protection against ground moisture and water place the equipment and crates on pallets wooden beams or foundations Ensure that the air circulation under the equipment is not impeded Place wooden spacer blocks between the covers and the device Do not place covers or tarpaulins completely around the equipment on the floor NOTICE Damage to the device as a result of incorrect storage Incorrect or ex...

Page 60: ... units Refer to the operating instructions of the re cooling unit for notes relating to transport and storage NOTICE Damage to the ion exchange cartridge as a result of frost If the ion exchange cartridge is exposed to frost it may be damaged Only transport and store the ion exchange cartridge in non frosty conditions More information is available in the re cooling unit s operating instructions Pr...

Page 61: ...injury or material damage Replace the defective seals before commissioning Observe the environmental conditions stated in the technical data Danger as a result of dirt and pollution inside the device When performing mounting and installation work dirt can accumulate inside the device when the doors are open Dirt deposits can can mean that the requirements relating to cleanliness are no longer fulf...

Page 62: ...described in Section Preparing for use See also Opening the device Page 94 Overheating caused by closed water valves If the water valves are closed when operational the drive can overheat This can damage the components Open all of the water valves after installing the drive 5 2 Tools required You require the following tools for mounting and installation Wrench or socket wrench width across the fla...

Page 63: ... Preparation Ensure that access to the holes in the bottom of the cabinets is unobstructed Remove the guard covers To screw the transport units together you will need the following mounting hardware Hexagon nuts ISO 4032 M8 8 A2L Contact washers SN70093 8 FSt mechZn f Threaded pin M8 x 15 5 Self adhesive sealing strips Screwing the transport units together To screw transport units together proceed...

Page 64: ...for M12 screws are provided on each cabinet panel to secure the cabinet to the foundation Information on mounting holes and their fixing dimensions are specified in the dimension drawing Install the transport units in accordance with the specifications provided in the accompanying dimension drawings When doing this maintain the specified distance between the top of the cabinet and the ceiling Asse...

Page 65: ...tely If several cabinets are set up as one unit the grounding connections of the individual cabinets must be connected with each other A grounding lug connection cable is supplied with each cabinet To connect the ground connections for several cabinets proceed as follows 1 Insert the grounding cable through the side panel of the cabinet Figure 5 2 Connecting the grounding for the cabinet units 2 S...

Page 66: ...e and skin injuries caused by deionized water Deionized water is harmful to eyes and skin and can damage surfaces Therefore use appropriate protective clothing for all work on the drive However if your eyes or skin do come into contact with deionized water rinse the affected area thoroughly with tap water as soon as possible If deionized water leaks out eliminate the source of the problem and remo...

Page 67: ...e deionized water piping of the drive Refer to the associated information about the ionized water connections in the dimension drawing The inlet and outlet pipes are appropriately marked When connecting the re cooling unit ensure that the inlet pipe and return pipe are connected correctly Only use the supplied connecting pipes Hand tighten the union nut of the connecting pipe for the inlet and ret...

Page 68: ...Assembly 5 6 Connecting the water circuits SINAMICS PERFECT HARMONY GH150 6SL3825 68 Operating Instructions 05 2020 ...

Page 69: ... with defective seals can result in death serious injury or material damage Replace the defective seals before commissioning Observe the environmental conditions stated in the technical data Injury caused by short circuit Damaged cables or their improper routing can cause damage to property and personal injury Only use cables that are completely intact and not damaged Correctly route the cables Do...

Page 70: ...escribed in Section Preparing for use See also Opening the device Page 94 Note Control and signal lines must always be connected according to the circuit diagrams supplied with the unit Detailed information about connecting the components is given in the interconnection diagram Note We recommend using shielded cables Unshielded cables can transfer disturbances to the control and signal lines and l...

Page 71: ...round potential the immunity to interference is increased For this reason you are advised to lay these cables along edges and at ground potential Ground the reserve cores on at least one end In order to avoid additional locations where interference can be coupled in long cables should be shortened or routed where there is little interference If conductors or cables conduct signals of different cla...

Page 72: ... so that it covers the greatest possible surface area Use ground clamps ground terminals or ground screw connections Avoid extending the cable shield to the grounding point using a wire This reduces the shield effectiveness by up to 90 Electrical connection 6 2 Electromagnetic compatibility SINAMICS PERFECT HARMONY GH150 6SL3825 72 Operating Instructions 05 2020 ...

Page 73: ...incorrectly connected cable shields Incorrect connection or damaging of the cable shield can impair the function of the system Handle the cable shield carefully Ensure that the cable shield is correctly connected Bridge shield gaps at terminals circuit breakers contactors etc with minimum impedance and through the largest possible surface area Shield busbars Cables Terminals Figure 6 2 Bridging sh...

Page 74: ... of contactors and relays in the device In order to reduce noise interference entering or exiting via the cable filter auxiliary voltages in the control cabinet 6 3 Potential concept A noise free connection between the internal and external supply voltage can be achieved by connecting the 0 V potentials to each other and grounding them This also eliminates the need for the control circuit insulati...

Page 75: ...ring equipment ground the device A grounding busbar is located in the lower section of the cabinets The grounding busbar is used to ground the components installed in the cabinet and to ground the cabinet itself 1 To ensure safe drive operation connect a protective grounding conductor to the grounding busbar 2 Connect the grounding cable of the foundation to the grounding busbar Foundation Groundi...

Page 76: ...or housing Also connect the shield to the shield rail Do not connect the cable shield to a ground pin of the connector The connector housing and front plate of the boards do not provide adequate cable shielding Connect the cable shields at both ends to the shield rails in the cabinets Always use shielded analog signal cables regardless of whether they are installed inside or outside cabinets In or...

Page 77: ...nder Technical specifications and drawings See also Technical data and drawings Page 135 6 8 Connecting power cables 6 8 1 Preparations When connecting the cables observe all the conditions regarding conductor protection Do not exceed the permitted cable lengths between the converter output and motor The distance between the motor cable and the signal cable should be at least 20 cm Do not lay grid...

Page 78: ...ore screwing the connections Apply a thin layer of grease to the screws Table 6 2 Cleaning agents and grease Materials required Cleaning agent Ethyl alcohol Grease 2G from Elektrolube NOTICE Thermal destruction of the power cable Cables that have not been properly secured at the connection point represent a high electrical transition resistance which can result in thermal destruction Tighten the s...

Page 79: ...le on the cable support bar using cable clips 6 8 3 Shield connection Only use shielded medium voltage cables to reduce cable conducted radio frequency interference RFI and to achieve the appropriate EMC compatibility The cable shield must be uninterrupted over the complete length of the cable and must comprise non magnetic material Preferably use cables with foil type shields Do not connect other...

Page 80: ... re cooling unit to the drive Connect the cable provided for the cooling unit to the corresponding interfaces on the drive and the cooling unit Further details are contained in the circuit diagram of the drive and the re cooling unit 6 10 Interconnecting optional connections Depending on the range of options installed further connections have to be interconnected Detailed information about interco...

Page 81: ... the cable ties around the entire cable duct The cable ties must be located at the same positions as in the delivered state Figure 6 7 Schematic diagram Fastening the cable ties Electrical connection 6 11 Fastening the cable ducts with cable ties SINAMICS PERFECT HARMONY GH150 6SL3825 Operating Instructions 05 2020 81 ...

Page 82: ...Electrical connection 6 11 Fastening the cable ducts with cable ties SINAMICS PERFECT HARMONY GH150 6SL3825 82 Operating Instructions 05 2020 ...

Page 83: ...lt in death serious injury or material damage Incorrectly performed commissioning can result in the warranty becoming null and void Never commission the device if it is dirty or polluted Immediately contact Customer Support if it is polluted You can find the relevant contact person under Service Support Page 133 This device may only be commissioned by electrically skilled persons who have been ade...

Page 84: ...ARTER Commissioning Testing Drive optimization Diagnostics The STARTER software is available in SIOS under the following link hot spot text https support industry siemens com cs ww en view 26233208 Commissioning 7 3 STARTER software SINAMICS PERFECT HARMONY GH150 6SL3825 84 Operating Instructions 05 2020 ...

Page 85: ...urther information on alarms and faults in the section Indicating and rectifying faults If it is not possible to simply rectify a fault inform the manufacturer s service personnel immediately For additional information see the Service Support chapter Danger when operating with ground fault The type and location of the fault cannot be established just from a ground fault error message For example t...

Page 86: ...al contains an overview of all parameters as well as a selection of function diagrams to describe the operating principle 8 2 Operating the converter Only trained personnel may operate the converter 8 3 Functions Note List manual References to functions function plans and parameters are found in the list manual for the drive 8 3 1 Monitoring functions and protective functions The drive features ha...

Page 87: ...est The A Isometer performs an automatic self test under the following conditions When the insulation resistance of the line supply 20 MΏ Every 24 hours when an output relay for the system error message has been preselected Terminal monitoring The connections to mains and ground PE are monitored continuously If the cables are interrupted or not connected or if their resistance is high this is indi...

Page 88: ...and rectifying faults The drive provides many protection functions These protection functions protect the drive against damage in a fault situation A distinction is made between the following messages Fault A fault is a message from the drive indicating a fault or other exceptional unwanted state The cause can be a fault in the drive itself or also an external fault This fault for example could ha...

Page 89: ...l board voltage fault Check input voltage If input voltage is 18 V and LED red Return component for repair Green Continuous light 24 V power supply OK Internal board voltages OK RUN ERR Off The electronic power supply is missing or lies outside the permissible tolerance range Green Continuous light The component is ready for operation and cyclic DRIVE CLiQ communication is in progress Orange Conti...

Page 90: ...ase circuits On Not actuated Actuated Closed Actuated Not actuated Open Not actuated Not actuated Open Fault Relay jammed Motor contactor jammed Defect in electronics Open Cross circuit ground fault in EMERGENCY STOP circuit no supply voltage Operation 8 4 Fault and system messages SINAMICS PERFECT HARMONY GH150 6SL3825 90 Operating Instructions 05 2020 ...

Page 91: ...seals before commissioning Observe the environmental conditions stated in the technical data Electric shock caused by externally connected high voltages Magnetizing and demagnetizing equipment that is fed from an external voltage source can result in high voltages This voltage can result in death or serious injury Carefully comply with the 5 safety rules Ensure that no voltage from external feeds ...

Page 92: ...te The actual intervals at which maintenance procedures are to be performed depend on the environmental and operating conditions Define maintenance intervals that reflect your plant specific environmental and operating conditions and meet your availability requirements When doing so take the prescribed maintenance intervals into consideration as well as the instructions for repairing and replacing...

Page 93: ...e condition Always observe the five safety rules Page 15 when carrying out any work on the device 9 2 1 Grounding using the grounding harness 1 Secure the terminal of the grounding harness to the lower fixed sphere 2 Secure the terminals of the grounding harness to the upper fixed spheres Attaching the grounding spider Upper fixed spheres Lower fixed sphere Figure 9 1 Schematic diagram Attaching t...

Page 94: ...on at the phase connection is fulfilled None of the cell controls supplies status information The cell electronics no longer operate below a cell voltage of 200 V As a consequence status information is no longer transferred to the control The cell electronics no longer functions Up to the residual discharge 5 V the system waits for 5x the time constant of the discharge resistor and cell capacitor ...

Page 95: ...d Visual inspection clean if re quired Clean the cabinet interior Siemens service per sonnel Annually Visual inspection clean if re quired Check the external connections Owner After one year and ev ery four years there after Inspecting the cable clamps and screw terminals Check the internal connections Siemens service per sonnel After one year and ev ery four years there after Perform inspection a...

Page 96: ...nt at least once per year For more information please refer to the section Visual inspections Dust deposits inside the cabinet unit must be removed at regular intervals or at least once a year by qualified personnel in line with the relevant safety regulations Note The actual intervals at which maintenance procedures are to be performed depend on the environmental and operating conditions Define m...

Page 97: ...y defective parts immediately 9 4 3 6 Inspecting door limit switches Inspect the door limit switches regularly for contamination and corrosion Also verify that the the door limit switches function correctly at regular intervals 9 4 3 7 Checking the cooling circuit Check the entire cooling circuit for leaks If you find a leak in a pipe coupling tighten the nut by a turn Compare the measured conduct...

Page 98: ...op Service life of the fans The fans must also be fitted with a monitor to ensure that the drive operates reliably The service life of the device fans is 30 000 hours Replace the fan timely in order to maintain the reliable functioning of the cabinet unit 9 5 1 1 Replacing fans from the front Removing the fan The five safety rules must be observed Figure 9 2 Replacing fans from the front Maintenan...

Page 99: ...s can fall if incorrectly handled This can cause injury and material damage Please take special care when removing the fans from the drive Installing the fan Install the fan in reverse order 9 5 1 2 Replacing fans from the back Removing the fan The five safety rules must be observed Figure 9 3 Schematic diagram Replacing fans from the back 1 Remove the rear cover from the fan box 2 Loosen the conn...

Page 100: ...n damage the electronics This can result in malfunction Never use any type of chemical agent or liquid Only remove severe dirt and contamination after prior consultation with service experts for the particular product Use a dry clean lint free ESD cleaning cloth Wipe all external parts of the rack with it Make sure that the dirt is not distributed but actually removed by constant changes of the wi...

Page 101: ...s that are suitable for aluminum Use ESD compliant brushes and cloths Do not use cleaning cloths and brushes that have already been used to clean copper brass bronze or other heavy metals Use neither brass bronze or steel wire brushes nor cloths or steel wool interwoven with copper wire 9 7 Repair When carrying out any work carefully observe the information provided in Chapter Safety instructions ...

Page 102: ...equential damage can occur if the device is recommissioned but the repair work carried out was not complete Check whether secondary faults have occurred on components which have failed Replace the components involved Measures in the event of an error It is not possible to fully test repairs that are carried out on site Return the defective module back to the manufacturing plant for repair The rele...

Page 103: ...fier Power cell Diode power card or diode stack Sensors for conductivity pressure and temperature Operator panel CompactFlash card Low voltage components e g anti condensation heating fans contactors Bypass 9 7 2 Torques The following table contains the default values If the replacement of a component requires different torques they are specified in the associated sections Table 9 3 Tightening tor...

Page 104: ...able 9 4 Tightening torques for screw terminals for copper cables without cable lug 1 Screw type Set screws and headless screws Head screws with slit Head screws with hexagon profile nm in lb nm in lb nm in lb M2 M2 5 0 25 2 2 0 5 4 4 0 5 4 4 M3 0 3 2 7 0 6 5 3 0 6 5 3 M3 5 0 5 4 4 1 0 8 9 1 0 8 9 M4 0 8 7 1 1 3 11 5 1 3 11 5 M5 1 0 8 6 2 5 22 1 2 5 22 1 M6 1 3 11 5 3 0 26 6 3 5 31 0 M8 1 8 15 9 3...

Page 105: ...ules LEM current transformers or measuring resistors under any circumstances Do not make any changes to the design of the actual value acquisition Removing the AVT combination module 1 Follow the five safety rules Page 15 2 Release the control cables Carefully ensure that you do not kink the fiber optic cables 3 Remove the four fixing screws of the AVT combination module Figure 9 4 Example of an A...

Page 106: ...ween the current transformer and the AVT combination module To do this loosen the nuts on the side of the current transformer and remove the cables 5 Loosen the four screws that fix the current transformer to the busbar 6 Loosen the screw and the three screws that connect the busbar to the fixing plate When doing so keep a firm grip on the busbar to ensure it does not fall 7 Pull the busbar out to...

Page 107: ...age Follow the five safety rules Page 15 Before replacing the precharging transformer open the safety disconnector for the 400 V supply Lift the transformer carefully because it is heavy 45 kg Installing the precharging transformer 1 Remove the paint from at least one screw position on the base brackets This is where the transformer will be grounded 2 Install the new transformer in the reverse ord...

Page 108: ... spacing bolts 3 Remove all connecting leads If necessary remove the cable ties Note Note the core markings The cables are equipped with Faston connectors Make a note of the core markings When installing the new module note the core markings for the cables 4 Remove the module Installing a module Install the new module in the reverse order to when you removed it Maintenance 9 7 Repair SINAMICS PERF...

Page 109: ...oving a power cell Each power cell comprises two mechanical units which can be separated IGBT module weighing about 12 kg The capacitor bank with a weight of approx 44 kg Removing the power cells incorrectly can lead to serious injury and material damage When installing and removing the power cell do not position yourself below the individual units NOTICE Malfunction when replacing individual capa...

Page 110: ...tive power cell 1 Check that the power cells are in a no voltage condition at the A terminals of the power cell as well as the B connections of the capacitor bank 2 Remove the fiber optic cable at the front of the power cell 3 Remove the locking rings at the water couplings Remove the two water hoses including the couplings at the front of the power cell 4 Remove all screws M8 x 20 of the busbars ...

Page 111: ...citor busbar and the gating unit 10 Remove the gating unit by withdrawing it to the front Figure 9 8 Removing a power cell steps 8 10 11 Remove the screws M4 x 10 Withdraw the plate towards the front Figure 9 9 Removing a power cell step 11 Maintenance 9 7 Repair SINAMICS PERFECT HARMONY GH150 6SL3825 Operating Instructions 05 2020 111 ...

Page 112: ... 30 Remove the screw M8 x 16 of the capacitor bank Figure 9 10 Removing a power cell step 12 13 Withdraw the capacitor bank towards the front Maintenance 9 7 Repair SINAMICS PERFECT HARMONY GH150 6SL3825 112 Operating Instructions 05 2020 ...

Page 113: ... a value of 1 2 mF are installed The value in this example must have at least 6 mF up to max 6 3 mF with a tolerance of max 5 Any deviation of the measured capacitance signifies one or several defective capacitors In this case replace the capacitor bank NOTICE Malfunction when replacing individual capacitors It is not permissible to individually replace capacitors in the capacitor bank If this is ...

Page 114: ...e correctly inserted and interlocked shift the plastic ring towards the front and insert the locking ring NOTICE Damage to the gating unit if the locking ring is not inserted The gating unit can be damaged if the flow of water through the heatsink is not guaranteed In order to guarantee a reliable flow of water through the heat sink the locking ring must be correctly inserted After the water coupl...

Page 115: ...n death severe injuries and significant material damage You should always handle the capacitors as if they are charged Discharge the snubber circuit capacitors Short circuit the snubber circuit capacitors briefly before you withdraw the diode stack Tool required Socket wrench set Set of open ended wrenches Torque wrench up to 50 Nm Ratchet with short extension Ratchet length extension Side cutters...

Page 116: ...hinges on the bar Figure 9 12 Removing a door 3 Remove the cable ties that fix the water hoses Remove the front and rear spacers of the water hoses at the diode stack Unscrew the spacers in an anti clockwise direction Figure 9 13 Example diagram Removing the spacers Maintenance 9 7 Repair SINAMICS PERFECT HARMONY GH150 6SL3825 116 Operating Instructions 05 2020 ...

Page 117: ...nections 1 Remove the screws 2 Remove the busbar package To do this remove the screws Figure 9 14 Example diagram Removing the busbars Maintenance 9 7 Repair SINAMICS PERFECT HARMONY GH150 6SL3825 Operating Instructions 05 2020 117 ...

Page 118: ...9 15 Example diagram Removing the lower busbar package 4 Remove the Makrolon cover To do this remove the plastic screws Figure 9 16 Example diagram Removing the Makrolon cover Maintenance 9 7 Repair SINAMICS PERFECT HARMONY GH150 6SL3825 118 Operating Instructions 05 2020 ...

Page 119: ...ng with the inserted hose from the diode stack then the hose can be damaged as a result of the coupling teeth This can result in leaks To release the water inlets and outlets only withdraw the hose from the coupling CAUTION Eye and skin injuries caused by deionized water Deionized water is harmful to eyes and skin and can damage surfaces Therefore use appropriate protective clothing when you carry...

Page 120: ...Figure 9 18 Example diagram Releasing connections of the capacitor module Maintenance 9 7 Repair SINAMICS PERFECT HARMONY GH150 6SL3825 120 Operating Instructions 05 2020 ...

Page 121: ... cabinet towards the front CAUTION Risk of injury as a result of incorrectly handling the diode stack The diode stack is very heavy approx 30 kg When incorrectly handled the diode stack can cause injury and material damage Take special care when lifting the diode stack out of the drive Maintenance 9 7 Repair SINAMICS PERFECT HARMONY GH150 6SL3825 Operating Instructions 05 2020 121 ...

Page 122: ...oving capacitor modules 9 7 8 3 Installing Perform the installation in the reverse order to the steps described for the removal Comply with the specified torques The torques are listed in Section Repairing Also observe the notes in the following section Installing the capacitor group Figure 9 21 Wire jumper capacitor module Maintenance 9 7 Repair SINAMICS PERFECT HARMONY GH150 6SL3825 122 Operatin...

Page 123: ...components e g brackets which are not provided at on the new diode stack from the diode stack that you just removed Mount these parts and components onto the new diode stack When installing the diode stack always use new screws washers and nuts Insert the water hoses into the couplings up to the marking Fix the capacitor cables using cable ties Fasten the water hoses to the spacers using cable tie...

Page 124: ...s The sensors for detecting temperature conductivity and decreases in pressure are installed in the water piping NOTICE Device damage due to water If water enters the cabinet while a water sensor is being replaced this can result in material damage Before replacing a water sensor empty the entire water circuit and blow out the piping Before screwing into the adapter element seal the outer thread u...

Page 125: ...alling a sensor To install a sensor proceed as follows 1 Screw the sensor into the screw connection in the water pipe 2 Attach the connector to the sensor 3 Fasten the screws in the sensor cover 4 For the temperature sensor attach the cables directly to the sensor 5 Lock the sensor by using the two screws to screw the cover to the sensor Note Ventilating the deionized water circuit Vent the deioni...

Page 126: ...ot Figure 9 24 Remove the operator panel 4 Release the cables at the operator panel 5 Remove the screws 9 x of the fastening clips Remove the mounting clips Withdraw the operator panel from the cabinet door towards the front 6 Fit a new operator panel Fasten the operator panel 7 Connect the cables Maintenance 9 7 Repair SINAMICS PERFECT HARMONY GH150 6SL3825 126 Operating Instructions 05 2020 ...

Page 127: ...er is off Otherwise there is a risk of data loss or damage to the card which would prevent commissioning of the drive Only remove or insert the CompactFlash card when the power is switched off 2 Withdraw the CompactFlash card from the Control Unit Back up the data saved on it 3 Copy the stored data of the previous CompactFlash card to the new original Siemens card Note Invalid software key The sof...

Page 128: ...Maintenance 9 7 Repair SINAMICS PERFECT HARMONY GH150 6SL3825 128 Operating Instructions 05 2020 ...

Page 129: ...ys indicate the part number and if known the order number of the spare part required You can find the order number as follows The device label is attached to or next to each component Find out which item code the required spare part has The parts list provided specify the part number and where appropriate the article number corresponding to the equipment identifier For inquiries by email send a ph...

Page 130: ...Spare parts SINAMICS PERFECT HARMONY GH150 6SL3825 130 Operating Instructions 05 2020 ...

Page 131: ...ormation we assume that this substance does not represent any risk when correctly used including its disposal 11 2 Disposing of packaging material The packing is designed in such a way as to pose the minimum risk to the environment Some of the packaging can be recycled The disposal of packaging is controlled by country specific laws If in doubt ask your local disposal specialists or contact the lo...

Page 132: ...erious injury or material damage Only specialist personnel may disassemble and dispose of device components and old devices using appropriate protective clothing Shut down the device before disassembling Ground the device For old equipment observe the information in the Transport chapter For the following components pay special attention when disposing or reusing Batteries Capacitors PCBs Electron...

Page 133: ...request on site service or spare parts repairs You can find your local partner here https www lda portal siemens com siemlda en contact form Please have the following data ready Type MLFB Serial number You can find this data on the rating plate SINAMICS PERFECT HARMONY GH150 6SL3825 Operating Instructions 05 2020 133 ...

Page 134: ...Service Support SINAMICS PERFECT HARMONY GH150 6SL3825 134 Operating Instructions 05 2020 ...

Page 135: ...3 T11 IEC 60204 11 EU Directives 2014 35 EU amendments Low Voltage Directive 2014 30 EU amendments Electromagnetic Compatibility Insulation According to DIN EN 50178 VDE 0160 IEC 62103 IEC 61800 5 1 Pollution degree 2 without conductive pollution non condensing Protection class Class 1 according to DIN EN 61800 5 1 VDE 0160 T105 IEC 61800 5 1 Touch protection DIN EN 50274 VDE 0660 T514 and BGV A3 ...

Page 136: ...ermissible 2K11 according to DIN EN 60721 3 2 IEC 60721 3 2 3K3 according to DIN EN 60721 3 3 A2 1997 IEC 60721 3 3 Ed2 2 2008 Pollution degree 2 without conductive pollution according to DIN EN 50178 VDE 0160 IEC 62103 2 without conductive pollution according to DIN EN 50178 VDE 0160 IEC 62103 2 without conductive pollution according to DIN EN 50178 VDE 0160 IEC 62103 Mechanical ambient condition...

Page 137: ...lora Chemically active substan ces according to class 1C1 according to DIN EN 60721 3 1 IEC 60721 3 1 2C1 according to DIN EN 60721 3 2 IEC 60721 3 2 3C1 according to DIN EN 60721 3 3 A2 1997 IEC 60721 3 3 Ed2 2 2008 no occurrence of salt mist Mechanically active substan ces according to class 1S1 according to DIN EN 60721 3 1 IEC 60721 3 1 2S1 according to DIN EN 60721 3 2 IEC 60721 3 2 3S1 accor...

Page 138: ...Technical data and drawings B 2 Environmental conditions SINAMICS PERFECT HARMONY GH150 6SL3825 138 Operating Instructions 05 2020 ...

Page 139: ...uality verifications relating to the device such as declarations on the conformity of the device with directives or specifications in the Quality documents in a separate part of this manual SINAMICS PERFECT HARMONY GH150 6SL3825 Operating Instructions 05 2020 139 ...

Page 140: ...Quality documents SINAMICS PERFECT HARMONY GH150 6SL3825 140 Operating Instructions 05 2020 ...

Page 141: ...uments D In addition to these operating instructions further documents are provided that contain more information on commissioning and service SINAMICS PERFECT HARMONY GH150 6SL3825 Operating Instructions 05 2020 141 ...

Page 142: ...Additional documents SINAMICS PERFECT HARMONY GH150 6SL3825 142 Operating Instructions 05 2020 ...

Page 143: ...utdown 88 Undervoltage trip 23 88 Cleaning aluminum parts 101 Commissioning software 84 CompactFlash card Replacing 127 Components that can be destroyed by electrostatic discharge ESD Guidelines 19 Cooling circuit 45 Current transformer Torque 107 D DC link 30 39 40 88 Deionized water requirements 33 Door interlock 27 Cover screw 56 Electromechanical 39 94 Manual 56 Safety locking system 94 Double...

Page 144: ...l components 28 R REACH regulation 131 Re cooling unit Air filters 34 Conductivity of the deionized water 97 Connecting the cooling circuit 67 Deionized water 18 32 33 66 119 Deionized water specifications 33 Deposits of suspended solids 35 Dirt filters 34 Inadmissible additives 33 Ion exchanger 34 Monitoring the deionized water 33 Principle of operation 33 Raw water 32 35 Requirements 32 Specific...

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Page 146: ...Further Information www siemens com LDA Siemens AG Large Drives Applications Vogelweiherstr 1 15 90441 NÜRNBERG GERMANY ...