SINUMERIK 840D sl. Service - Configuring Commissioning. Manual (2011-2020)

SINAMICS drive line-up

4.4 Note for the installation clearance for the connection cables

4.4

Note for the installation clearance for the connection cables

4.4.1

General information

The arrangement of the components and equipment takes account of

● Space requirements

● Cable routing

● Bending radii of the connection cables

MOTION-CONNECT cables, refer to catalog PM21 or NC62

● Heat dissipation

● EMC

The components of the drive line-up should preferably be installed on a conductive mounting

surface to ensure low impedance between the component and the mounting surface.

Mounting plates with a galvanized surface are suitable.

Components are usually located centrally in a cabinet. The necessary mounting and

installation clearances above an below the components can, under certain circumstances,

exceed the minimum clearances specified in the product documentation.

The components can be arranged in one or more tiers. In a multiple-tier arrangement,

vertical installation or, in a cabinet row, side-by-side installation in different cabinet sections

is possible.

To determine the cross-section, use the DC link busbar current carrying capacity given in the

relevant technical data.

A ventilation clearance of 100 mm must be maintained around the line reactor (not including

the mounting surface).

DANGER

Risk of electric shock by incorrectly installed DC link bridge

Incorrectly installed DC link bridges at the left-hand end of the drive line-up can cause an

electric shock.

• Remove the DC link bridges including the screws on a 50 mm-wide Motor Module or DC

link module.

• Do not tighten the screws without the DC link bridges.

• For all components that are 75 mm wide or wider, the DC link bridges must not be

moved to the left or removed.

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SINAMICS drive line-up

4.4 Note for the installation clearance for the connection cables

4.4.2

Clearance of the Power Components

The installation clearance is defined by

● Ventilation clearance

● Cable clearance

Figure 4-22 Clearance in the vicinity of the power components

4.4.3

Ventilation Clearances of the SINUMERIK Components

Table 4- 2

Ventilation clearances above and below the components

Component

Clearance [mm]

NCU 7x0

80 mm

NX1x

80 mm

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4.5 Heat Dissipation of the Control Cabinet

4.5

Heat Dissipation of the Control Cabinet

4.5.1

Control cabinet cooling options

The following options are available for cooling the control cabinet:

● Filter fans

● Heat exchangers

● Cooling units

● Liquid cooling

● External air cooling

● External liquid cooling

The device to be used depends on the associated environmental conditions and the required

cooling capacity.

The air routing within the control cabinet and the cooling clearances specified must be

observed. No components may be installed and no cables routed in the cooling clearance

spaces.

NOTICE

Failure of components due to incorrect installation

Installing SINAMICS components incorrectly in the cabinet can reduce their service life and

cause them to fail prematurely.

• Observe the guidelines for installing SINAMICS components in the cabinet.

You must take into account the following specifications when installing a SINAMICS drive

line-up:

● Ventilation clearance

● Wiring and cabling

● Air guidance, air-conditioner

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SINAMICS drive line-up

4.5 Heat Dissipation of the Control Cabinet

4.5.2

General information on ventilation

SINAMICS components are force-ventilated using integrated fans, and in some cases

through natural convection. The fans are not equipped with temperature-dependent speed

control; only the states "on" or "off" exist.

The fans start when the pulse enable is set, and switch off with a small hysteresis as soon as

the temperature falls below the heat sink temperature saved in the power stack data

(typically 56 °C). The run-on time of the fan depends on various factors such as ambient

temperature, output current, duty cycle and, therefore, cannot be determined directly.

Note

For the 5 kW and 10 kW Smart Line Modules, the fan runs permanently.

WARNING

Risk of fire due to overheating as a result of insufficient ventilation clearances

Insufficient ventilation clearances can cause overheating and present a risk for personnel

due to smoke development and fire. This can also result in more failures and reduced

service lives of devices and systems.

• Maintain ventilation clearances of at least 80 mm above and below the components.

• Make sure that warm air can escape at the top.

• If you are using filter fans, heat exchangers, or air conditioners, make sure that the air is

flowing in the right direction.

WARNING

Risk of fire due to overheating resulting from covered ventilation slots

Covered ventilation slots can cause overheating and present a risk for personnel due to

smoke development and fire. This can also result in more failures and reduced service lives

of devices and systems.

• Route the connected signal and power cables to the components in such a way that

they do not cover the ventilation slots.

WARNING

Risk of fire due to hot spots resulting from a lack of air circulation in sealed cabinets

If air cannot circulate in the cabinet, this can lead to hot spots that present a risk for

personnel due to smoke development and fire. This can also result in more failures and

reduced service lives of devices and systems.

• Install an internal air circulation system that will ensure the air can flow.

• Install the fan above the components to optimize the air flow (suction).

Air circulation is not required if you are using switchgear with a passive heat dissipation

system.

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SINAMICS drive line-up

4.5 Heat Dissipation of the Control Cabinet

Note

The cooling air must flow through the components vertically from bottom (cooler region) to

top (region heated by operation).

The distance between the blow-out aperture of the air conditioner and the electronic

equipment must be at least 200 mm. With distances that are shorter than this, air baffle

plates must be used in order to divert the air.

①

Cooling unit

②

Control cabinet

Figure 4-23 Examples of cabinet ventilation

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SINAMICS drive line-up

4.5 Heat Dissipation of the Control Cabinet

NOTICE

Failure of components due to condensation

If air conditioners are used, the relative air humidity of the expelled air increases as the air

in the air conditioner cools and may exceed the dew point. If the relative humidity of the air

entering the SINAMICS components is over 80% for an extended period of time, it can be

assumed that the insulation of the components will fail as a result of electrochemical

reactions.

• Select the air guidance and arrangement of the cooling equipment in such a way that no

condensation can form on the components.

• Use air baffle plates, for example, to ensure that the cold air expelled from the air

conditioner mixes with warm air in the cabinet before it enters the components. This

reduces the relative air humidity to uncritical values.

• Prevent cold air from being blown directly onto electronic equipment.

• If required, install cabinet enclosure heating.

4.5.3

Cooling clearances

Table 4- 3

Cooling clearances required above and below SINAMICS components

Component

Clearance [mm]

CU320-2

Sensor Modules Cabinet-Mounted SMCxx

Terminal Modules TMx

Line filter for Line Modules

100

Active Interface Modules

Line reactors for Line Modules

100

Active Line Modules

16 kW - 55 kW

80 kW - 120 kW

80 (additional 50 in front of fan)

Smart Line Modules in booksize format

Basic Line Modules

Motor Modules Booksize

< 132 A

132 A and 200 A

80 (additional 50 in front of fan)

Braking Module Booksize

Control Supply Module

Capacitor Module

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4.5 Heat Dissipation of the Control Cabinet

4.5.4

Dimensioning Climate Control Equipment

Cabinet manufacturers provide calculation programs for selecting climate control equipment.

It is important to know the power losses for the components and devices in the control

cabinet.

Formula to calculate the power loss

q = Q - k • A • ΔT

q = thermal power that has to be dissipated through a refrigerator [W]

Q = internal power loss (incl. electronics losses) [W]

∆T = temperature difference between the room and cabinet interior [K]

k = heat transfer coefficient, e.g. sheet steel, painted 5.5 [W/(m² * K)]

A = freestanding cabinet surface area [m²]

Example

Table 4- 4

Power loss calculation for a drive configuration

Component

Number

Total power loss [W]

(including electronic losses)

CU320-2

Basic Line Filter for AIM/ALM 36

Active Interface Module 36 kW

340

Active Line Module 36 kW

666

Motor Module 18 A

185.4

370.8

Motor Module 30 A

309.2

927.6

SMC

SITOP 20

Line contactor

Total:

2469.4

● Assumption:

- freestanding cabinet surface area A = 5 m²

- temperature difference between the room and cabinet interior ∆T = 10 K

q = 2469.4 W - 5.5 W/(m² K) • 5 m²• 10 K = 2194.4 W.

See also

Power Loss of the SINUMERIK Components (Page 516)

Power loss of SINAMICS components (Page 516)

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SINAMICS drive line-up

4.6 Cooling of power units

4.6

Cooling of power units

With the SINAMICS S120 system, there are four distinct cooling methods for cooling power

units:

● Internal air cooling

● External air cooling

● Cold plate cooling

● Liquid cooling (liquid cooled)

4.6.1

Internal Air Cooling

All SINAMICS S120 booksize components are installed within a control cabinet. The total

heat loss of all components is dissipated in the control cabinet. There are three ways to

remove the heat from the control cabinet:

● Filter fans

● Heat exchangers

● Cooling units

The device to be used depends on the associated environmental conditions and the required

cooling capacity. The configuring must also maintain the specified clearances for the

ventilation. No other components may be placed in these areas.

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SINAMICS drive line-up

4.6 Cooling of power units

4.6.2

External Air Cooling

The external air cooling is a cooling system for SINAMICS booksize power units. The

through-hole technology is used for this construction form. The booksize power unit with its

heat sink can be placed in the rectangular cutout of the control cabinet rear wall and installed

with a seal. The heat sink with its cooling fins and fan (contained in scope of delivery)

extends at the back out of the control cabinet and the heat dissipation is made externally

from the control cabinet or in a separate air duct.

Figure 4-30 Installation of a booksize power section with external air cooling

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4.6 Cooling of power units

4.6.3

Cold plate cooling

Cold plate cooling is a cooling system for SINAMICS S120 booksize power units. The flat

aluminum cooling plate located at the rear side of the devices serves as thermal interface.

Special advantages of the cold plate technology

1. It is particularly suitable for machine concepts in which a high level of dirt accumulates in

the machine vicinity. The reduction of the cabinet-internal heat loss simplifies the heat

dissipation of a sealed control cabinet (IP54).

2. Advantageous for machine concepts for which liquid is already present in the process.

This heat dissipation method is thus suitable for both internal and external cold plate

cooling of the power components.

A distinction is made between:

● Cold plate with air heat sink

The components of the drive line-up are typically all attached with screws to the cooling

fins of an air heat sink.

● Cold plate with liquid heat sink

The components of the drive line-up are typically all attached with screws to the liquid

heat sink.

● Cold plate with internal liquid heat sink

This is considered to be a liquid cooling using a connection adapter. The liquid passes

through the integrated channels in the cold plate.

Note

Derating at a temperature of 40 °C and above

In the case of 300 mm-wide modules, derating must be applied due the heat transferred

to the external heat sink. If the temperature at the interface to the power unit is 40 °C,

derating is 20% for 6SL3136-7TE28-0AAx/6SL3126-1TE31-3AAx and 30% for 6SL3136-

7TE31-2AAx/6SL3126-1TE32-0AAx.

When the Active Line Modules and Motor Modules feature direct (internal) liquid cooling

(6SL3135-7TE31-2AA3/6SL3125-1TE32-0AA3), this derating does not apply to the cold

plate components referred to above.

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4.6 Cooling of power units

4.6.4

Liquid cooling (liquid cooled)

Liquid cooling is used only for large power units (Active Line Module 120 kW as well as

single Motor Module 200 A).

For liquid cooling, the power semiconductors are mounted on a heat sink, through which the

coolant flows. The power loss of the device is, to large extent, absorbed by the cooling

medium and can be dissipated outside the cabinet.

Additional references

/GH2/ SINAMICS S120 Booksize Power Modules, chapter "Cooling circuit and coolant

properties".

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Communication within the system

5.1 Communication overview

Note

The significance of items ① to ⑤ is explained on the pages that follow.

① (NCU)

● IP assignment of the server

● The ports need to be activated if VNC and HMI/Step7 are to be used (SW2.4.xxx and

higher):

/user/system/etc/basesys.ini

[LinuxBase]

FirewallOpenPorts="TCP/102 TCP/5900"

② (S7 Hardware Config)

Access parameters need to be set in the S7 hardware configuration.

1. Check the network connection (ping on selected access path X120/X130/X127).

2. Select the PG/PC interface in SIMATIC Manager.

Note

Do not select "TCP/IP (AUTO)…" or "ISO Ind. Ethernet ..." under any circumstances!

3. Set parameters for HW Config → Machine control panel using the selected access IP

address (X120/X130/X127).

4. Load the parameter assignment to the station.

Note

As of SW 2.4:

The ports must first be activated where connections via the company network are

involved (X130).

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Communication within the system

5.1 Communication overview

③ (PG/PC)

On the system network (X120):

On the service network (X127):

• TCP/IP Internet protocol

- properties

- general

- Set fixed IP addresses

- IP address obtained automatically

• Example:

- IP: 192.168.214.250

- Sub.: 255.255.255.0

④ (System Network Center > TCU support)

When TCU - PCU50.5 (HMI Advanced) is powered up, the IP address of the PCU must be

entered in the

/user/common/<TCU-Name>/common/tcu/config.ini

file:

[Station]

mcpIndex=…

tcuIndex=…

dckEnable=…

MaxHostIndex=1

[host_1]

Address=192.168.214.241

● If the DHCP of the NCU (X120) is active:

Set the "Settings system network" program on the "TCU support" tab.

● Set "No boot support".

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Communication within the system

5.1 Communication overview

⑤ (machine control panel - Industrial Ethernet)

Note

The Service menu (Backup/Restore) is only available for an analog monitor, TCU OP, or

PCU OP.

● mcp_client.ini file:

- copy mcp_client.ini from

/siemens/sinumerik/mcp_client/mcp_client.ini

/user/sinumerik/mcp_client/mcp_client.ini

- "addrMode" change: 1=DNS (default) 0=HWS

This may be required after a change of software if the machine control panel no longer

uses PROFIBUS for communication

● Organization block 100 (OB100):

CALL "RUN_UP" , "gp_par

"MCPNum :=1

MCP1BusAdr :=192 // bus address in accordance with MCP switch

MCPMPI :=FALSE

MCPSDB210 :=FALSE

MCPCopyDB77 :=FALSE

MCPBusType :=B#16#55 (PROFIBUS = 3)

Note

In B#16#55, the initial "5" refers to the first machine control panel and the last "5" refers to

the second.

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Communication within the system

5.2 DRIVE-CLiQ Topologies

5.2

DRIVE-CLiQ Topologies

5.2.1

DRIVE-CLiQ topology

Introduction

DRIVE-CLiQ (Drive Component Link with IQ) is a communication system for connecting the

various SINAMICS components (e.g. Control Unit, Line Module, Motor Modules, motors, and

encoders).

In SINAMICS contexts, the term "topology" refers to the structure of a drive system, including

its DRIVE-CLiQ wiring and other wiring elements.

DRIVE-CLiQ supports the following functions:

● Automatic detection of components by the Control Unit (NCU 7x0.3 or CU320-2)

● Standard interfaces to all components

● Standardized diagnostics down to component level

● Standardized service down to component level

Electronic rating plate

DRIVE-CLiQ components have an electronic type plate in which the characteristic device

data is stored. When connecting the device to the Control Unit, the following information is

transferred via DRIVE-CLiQ:

● Component type (e.g. SMC20)

● Order number (e.g. 6SL3055-0AA0-5BA0)

● Manufacturer (e.g. SIEMENS)

● Hardware version (e.g. A)

● Serial number (e.g. T-PD3005049)

● Technical data (e.g. rated current)

Actual topology

The actual topology is the actual DRIVE-CLiQ cabling tree, which is detected automatically

via DRIVE-CLiQ when the drive system components are started up.

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Communication within the system

5.2 DRIVE-CLiQ Topologies

Target topology

The target topology is stored on the memory card on the Control Unit and is compared with

the actual topology when the Control Unit is started up.

The target topology can be specified in two ways and saved on the memory card:

● Via the SINUMERIK 840D sl drive wizard or via the STARTER commissioning tool (by

creating the configuration and loading it to the drive unit)

● Via quick commissioning (automatic configuration):

the actual topology is read and the target topology written to the memory card.

Comparison of topologies at Power On

Comparing the topologies prevents a component from being controlled/evaluated incorrectly

(e.g. drive 1 and 2).

When the drive system starts up, the Control Unit compares the detected actual topology

and the electronic rating plates with the relevant target topology stored on the memory card.

You can specify how the electronic rating plates are compared for all the components of a

Control Unit via p9906. The type of comparison can be changed subsequently for each

individual component. You can use p9908 for this or right-click in the topology view in the

STARTER tool. All data on the electronic rating plate are compared by default.

The following data in the target and actual topologies is compared depending on the settings

made in p9906/9908:

● p9906/p9908 = 0 component type, order number, hardware version, manufacturer, serial

number

● p9906/p9908 = 1 component type, order number

● p9906/p9908 = 2 component type

● p9906/p9908 = 3 component class (e.g. Sensor Module or Motor Module)

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5.2 DRIVE-CLiQ Topologies

Figure 5-2

Topology of the SINUMERIK drive wizard

Note

The Control Unit and the Option Board are not monitored. A replacement of components

is accepted automatically and not displayed.

5.2.2

DRIVE-CLiQ wiring

Note

Unless otherwise specified, Control Unit always refers to a SINUMERIK NCU 7x0.3 in the

information below.

Note

The components of the SINAMICS S120 drive family and the Control Unit are interconnected

using DRIVE-CLiQ. When connecting the components, please note the following rules.

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Communication within the system

5.2 DRIVE-CLiQ Topologies

Rules for wiring DRIVE-CLiQ

Boundary conditions

● On the SINUMERIK 840D sl, only SERVO control is possible. Vector operation is not

possible.

● The following information about quantity structures only applies if Terminal Modules of

type TM120 alone are being used. With a sampling time of 125 μs, a maximum of two

TM120 modules are allowed; with 62.5 μs, a maximum of one.

● Add-ons in addition to the linear axis or the rotary safety axis are not permitted.

● The current hardware configuration specifies the components to be considered.

Deactivated drive objects/Sensor Modules must also be taken into account in the quantity

structure.

● SINUMERIK Safety Integrated is intended for all axes.

● PROFIBUS DP ≥ 2 ms cycle

SINUMERIK Safety Integrated ≥ 12 ms cycle

● The sampling times are set using parameter p0112:

p0112 = 3: Standard (125 μs)

p0112 = 4: High Performance (62.5 µs)

p0112 = 5: High Performance (31.25 µs)

MANDATORY conditions

● A maximum of 14 nodes are permitted on an NCU DRIVE-CLiQ socket. A Double Motor

Module counts as two components. The maximum possible number of nodes is reduced

in the case of a faster clock rate.

Clock rate

Max. number of nodes

125 μs

62.5 μs

31.25 μs

Dependence of clock rate and number of nodes on a DRIVE-CLiQ interface

● Drive modules are connected in series (line topology) with the Motor Modules. Ring wiring

is not permitted. The measuring systems assigned to these drives must relate to the

same Control Unit or NX.

● A maximum of eight nodes in series is permissible. A Double Motor Module counts as two

nodes. A row is always regarded as starting at the control unit.

● NX modules must be wired from the NCU using a point-to-point configuration. Cascading

is not permitted. NX modules may not be operated downstream of a DRIVE-CLiQ hub or

another DRIVE-CLiQ component.

● The components may not be double-wired, i.e. a DRIVE-CLiQ component must not be

associated with two DRIVE-CLiQ cables.

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Communication within the system

5.2 DRIVE-CLiQ Topologies

● Only one ALM/SLM may be connected per Control Unit. The DC links of different

ALMs/SLMs may not be connected to one another.

● To enable the "Automatic configuration" function to assign the encoders to the drives, the

rules below must be observed:

- The connection from the Control Unit to the first infeed and the first Motor Module

must each be established at the X200 interface.

- The DRIVE-CLiQ cables between the Motor Modules must each be connected from

the X201 interface to the X200 interface on the next component.

- The power line to the motor and the associated motor encoder must be connected to a

Motor Module.

- The following applies to Double Motor Modules:

X200: from the previous node

X201 standard assignment: to the next node or SMx for 2nd axis

X202 standard assignment: SMx 1st axis

X203 standard assignment: SMx 2nd axis

Figure 5-3

DRIVE-CLiQ topology for NCU 7x0.3

Note

ALM and Motor Modules should preferably have a star topology

The Active Line Module and the Motor Modules can also be connected with a line topology.

In order to achieve more uniform utilization, however, a star topology (i.e. connection to

separate DRIVE-CLiQ lines) is preferable.

Tips for optimum commissioning

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Communication within the system

5.2 DRIVE-CLiQ Topologies

● The Active Line Module or Smart Line Module should always be assigned the DO number

"2".

● The motor measuring systems should be connected to the associated Motor Modules

(X202/X203).

● NX modules should always be populated on the NCU from the rear. This means that they

will automatically be assigned with PROFIBUS addresses in reverse order (15 - 12).

● A DRIVE-CLiQ hub should ideally be attached to a separate DRIVE-CLiQ port on the

NCU, so as not to exceed the maximum quantity structures of DRIVE-CLiQ components.

If there are no free connectors here, the DRIVE-CLiQ hub is connected to the last Motor

Module (observe the rule of 14 components in a line, and a maximum of eight of these in

series).

● A DRIVE-CLiQ cycle of less than 125 μs should only be used if an increased pulse

frequency is necessary due to an increased speed.

● A Double Motor Module, a DMC20, and a DME20 each correspond to two DRIVE-CLiQ

nodes. This also applies to Double Motor Modules, at which just one drive is configured.

● If the current controller sampling time for a drive object has to be changed in such a way

that the modified sampling time is no longer in line with the other drive objects on the

DRIVE-CLiQ line, the following options are available:

- Reconnect the drive object to a separate DRIVE-CLiQ line.

- Change the current controller sampling times and/or the sampling times of the

inputs/outputs of the other drive objects so that they fit into the new pattern.

Maximum quantity structures for stand-alone system and extended systems

Table 5- 1

Standard applications with the same DQ cycle

Quantity structures

DQ cycle

NCU

ALM

Motor

Direct

DRIVE-

Module

measuring

CLiQ Hub

systems

Stand alone

125 μs

1-5

NX15

125 μs

NX15

62.5 μs

NX15

31.25 μs

NX10

125 μs

NX10

62.5 μs

Table 5- 2

Special applications with mixed DQ cycle

Quantity structures

DQ cycle

NCU

ALM

MoMo

Motor

Direct

DRIVE-

62.5 μs

125 μs

measuring

CLiQ Hub

systems

Stand alone

mixed

1-5

NX15

mixed

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Communication within the system

5.2 DRIVE-CLiQ Topologies

Specifications for sampling times

● For Active Line Modules in booksize format, only a current controller sampling time of

125.0 µs or 250.0 µs can be set.

● A current controller sampling time between 31.25 µs and 250.0 µs can be set for servo

drives (31.25 µs ≤ p0115[0] ≤ 250.0 µs).

● For servo drives with a current controller sampling time of p0115[0] = 62.5 µs, the

following applies:

- only possible in booksize and blocksize format

- maximum quantity structure:

- booksize: 2x servo with p0115[0] = 62.5 µs + Line Module (connected to a different

DRIVE-CLiQ line)

- servo drives in booksize format can be combined on one DRIVE-CLiQ line with a

servo with p0115[0] = 125.0 µs (but with same quantity structure).

- A DRIVE-CLiQ hub DMC20 cannot be operated with servo drives with p0115[0] =

62.5 µs on a DRIVE-CLiQ line but must instead be connected to a separate DRIVE-

CLiQ line.

- blocksize: 1 servo with p0115[0] = 62.5 µs

● When a unit in chassis format is connected to a DRIVE-CLiQ line, the smallest current

controller sampling time must be at least 250 µs.

Example: A mixture of chassis and booksize units on a DRIVE-CLiQ line.

● Motor Modules in chassis format with different current controller cycles must be

connected to separate DRIVE-CLiQ lines. For this reason, Chassis Motor Modules and

Booksize Motor Modules with a current controller sampling time < 250 µs must also be

connected to separate DRIVE-CLiQ lines.

● The sampling times (p0115[0] and p4099) of all components that are connected to a

DRIVE-CLiQ line must be divisible by one another with an integer result.

Table 5- 3

Connecting the motor encoder to the Motor Module via DRIVE-CLiQ

Component

Connecting the motor encoder via DRIVE-CLiQ

Single Motor Module booksize

• Encoder at X202

Double Motor Module booksize

• Motor connection X1: Encoder at X202

• Motor connection X2: Encoder at X203

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Line connection

6.1 Power Supply Interface Variants

Note

Line connection of motors

In combination with the drive system, the motors are generally approved for operation on TN

and TT systems with grounded neutral point and on IT systems.

When operated on IT systems, the occurrence of a first fault between an active part and

ground must be signaled by a monitoring device. In accordance with IEC 60364-4-41, it is

recommended that the first fault be eliminated as quickly as is practically possible in order to

minimize the temporary overload of the motor insulation.

In all other systems, except TN and TT systems with a grounded neutral point and IT

systems such as systems with a grounded line conductor, an isolation transformer with

grounded neutral point (secondary side) must be connected between the line system and the

drive system in order to protect the motor insulation from excessive stress.

6.1.2

Operation of the line connection components on the supply network

The SINAMICS S Booksize converter system is rated for direct operation on TN, TT, and IT

line supply systems with a rated voltage of 380 V 3 AC to 480 V 3 AC.

Figure 6-2

Direct operation on the line supply

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6.1 Power Supply Interface Variants

6.1.3

Operating line connection components via an autotransformer

An autotransformer can be used to adapt the voltage in the range up to 3-ph. 480 VAC

+10%.

DANGER

Risk of electric shock

To ensure protective separation an isolating transformer must be used for voltages greater

than 3-ph. AC 480 VAC +10%.

Applications:

● The motor insulation must be protected from excessive voltages.

● The Active Line Module must supply a regulated DC link voltage. This is possible with a

rated voltage of 380 V to 415 V.

A combination with motors that may be operated with a DC link voltage of up to 660 V,

and a line voltage > 415 V requires a controlled DC link voltage.

Figure 6-3

Operation of a Line Module via an autotransformer

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6.1 Power Supply Interface Variants

6.1.4

Operating line connection components via an isolating transformer

An isolating transformer converts the line supply type of the plant or system (e.g. IT/TT

system) to a TN system. Additional voltage adaptation to the permissible voltage tolerance

range is possible.

An isolating transformer must be used in the following cases:

● The insulation of the Motor Module and/or the motor is not suitable for the voltages that

occur.

● There is no compatibility with an existing residual-current protective device.

● The installation altitude is greater than 2000 m above sea level.

● A line filter should be used in a line supply system that is not a TN line supply system with

grounded neutral conductor.

DANGER

Danger to life through electric shock

If the line supply voltage is greater than 480 V +10%, it is not permissible to use an

autotransformer.

An isolating transformer must be used to ensure protective separation.

An isolating transformer must have the following properties:

● The transformer secondary must be in the star connection (a delta connection is not

permissible).

● The neutral conductor must be brought out. It must be connected to the PE of the line

filter, line reactor or AIM and Line Module (infeed).

Caution: If the neutral conductor is not brought out and/or not connected, then all of the

restrictions of an IT system apply.

● If the line supply is available in a star connection on the primary side, then the vector

group that is required is: Yyn0

● If the line supply is available in a delta connection on the primary side, then the vector

group that is required is: Dyn5

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6.1 Power Supply Interface Variants

6.1.5

Residual-current operated circuit breakers (RCD)

Residual-current operated circuit breakers (RCD) can be used in addition to the overcurrent

protection devices provided. They are the preferred solution for operation on TT systems.

WARNING

Danger to life through electric shock due to unsuitable overcurrent protective devices

Residual-current operated circuit breakers alone are not permissible to provide protection

against direct and indirect contact. Always install residual-current protective device in

addition to suitable overcurrent protective devices.

Note

Operation on residual-current operated circuit breakers is currently only possible with Line

Modules up to and including 36 kW.

Observe the following conditions when using residual-current operated circuit breakers:

● Only use a delayed tripping, selective AC/DC-sensitive residual-current operated circuit

breaker, type B.

● Ensure compliance with the max. permissible ground resistance of the "selective

protective device" (83 Ω max. for residual-current devices with 0.3 A rated differential

current).

● Connect parts of the drive system and the machine that can be touched to the system's

protective conductor.

● Check the total length of the shielded power cables (motor cables incl. line supply

conductors from line filters to the connecting terminals of the Line Module) in the drive

line-up. The total length must be less than 350 m.

● Only operate the system with the recommended line filters.

● Only connect one residual-current operated circuit breaker in series. Cascading is not

permissible.

● Ensure that the switching elements (disconnector unit, contactors) for connecting and

disconnecting the drive system have max. 35 ms delay time between the closing/opening

of the individual main contacts.

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6.1 Power Supply Interface Variants

Figure 6-5

Connecting a residual-current operated circuit breaker

Recommendation

SIEMENS selectively switching AC/DC-sensitive residual-current circuit-breakers according

to EN 61009-1 of the 5SM series (e.g. 5SM3646-4 or 5SM3646-4+5SW3300 with an

auxiliary disconnector (1 NC contact / 1 NO contact) for a rated current of 63 A and rated

fault current of 0.3 A (see Catalog "BETA Modular Installation Devices - ET B1")).

Note

AC or pulse-sensitive RCCBs are not suitable.

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6.1 Power Supply Interface Variants

6.1.6

Residual-current monitors (RCM)

Used in conjunction with appropriate circuit breakers, residual-current monitors (RCMs)

provide fire and system protection even at high levels of grounding resistance (in TT

systems, for example). When operating on TT systems for infeed powers exceeding 55 kW,

and with systems that extend across a large area, residual current monitors must be installed

in addition to the appropriate circuit breakers.

WARNING

Fire hazard and danger of a plant standstill when residual currents occur

Residual currents in the power supply that are not detected can cause fires and failures in

the entire system.

• Always install residual-current monitors in conjunction with suitable circuit breakers.

Note the points below when using residual-current monitors:

● Only use AC/DC-sensitive RCM type B devices with delayed tripping that guarantee

reliable tripping even for smoothed DC residual currents.

● Connect parts of the power drive system and the machine that can be touched to the

system's protective conductor.

● Do not route the protective conductor through the measuring current transformer, as this

would cancel its protection function.

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6.1 Power Supply Interface Variants

Figure 6-6

Connecting a residual-current monitor

Recommendation

● Bender AC/DC-sensitive residual-current monitor RCMA471LY, with measuring current

transformer W120B (120 mm) or W210B (210 mm)

● Circuit breaker with thermal overload release, short-circuit release, and undervoltage

release

To protect the units against line-side surge voltages, you are advised to install an

overvoltage protection device directly at the infeed point (upstream of the main switch). To

fulfill the requirements of CSA C22.2 no. 14-05, surge protection is essential. For examples

of suitable voltage surge arresters, see www.raycap.com (for example)

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6.2 Overcurrent protection by means of line fuses and circuit breakers

6.2

Overcurrent protection by means of line fuses and circuit breakers

Line fuses or, preferably, circuit breakers must be used for line/overcurrent protection in

order to limit the damage to a Line Module if a fault occurs. NH, D, and DO type fuses with a

gL characteristic or suitable circuit breakers according to IEC 60947 can be used for this

purpose.

Table 6- 1

Recommended line fuses and circuit breakers for Active Line Modules

16 kW

36 kW

55 kW

80 kW

120 KW

In fuse

35 A

80 A

125 A

160 A

250 A

LV HRC line fuse

3NA3 814

3NA3 824

3NA3 132

3NA3 136

3NA3 144

Circuit breaker

3RV1031-4FA10

3RV1041-4LA10

3VL2712-1DC33

3VL3720-1DC33

3VL3725-1DC36

(IEC 60947)

UL-application

Rated current

35 A

80 A

125 A

175 A

250 A

Line fuse ¹⁾

AJT35

AJT80

AJT125

AJT175

AJT250

Circuit breaker

3VL1135-2KM30

3VL2108-2KN30

3VL2112-2KN30

3VL3117-2KN30

3VL3125-2KN30

1) Type AJT class J, source of supply: Ferraz Shawmut

Table 6- 2

Recommended line fuses and circuit breakers for Smart Line Modules in booksize and booksize compact

format

5 kW

10 kW

16 kW

36 kW

55 kW

In fuse

16 A

35 A

80 A

125 A

LV HRC line fuse

3NA3 805

3NA3 814

3NA3 824

3NA3 132

Circuit breaker

3RV1031-4BA10

3RV1031-4FA10

3RV1041-4LA10

3VL2712-1DC33

(IEC 60947)

UL-application

Rated current

17.5 A

35 A

80 A

125 A

Line fuse ¹⁾

AJT17-1/2

AJT35

AJT80

AJT125

Rated current

20 A

35 A

80 A

125 A

Circuit breaker

3VL1102-2KM30

3VL1135-2KM30

3VL2108-2KN30

3VL2112-2KN30

1) Type AJT class J, source of supply: Ferraz Shawmut

If used in conjunction with a residual-current monitor (RCM), circuit breakers providing an

"undervoltage tripping" option should be used, with the following suffixes added to the order

numbers:

...-2AJ0 for 380 VAC - 415 VAC

...-2AK0 for 440 VAC - 480 VAC

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6.3 Line Contactor Control

WARNING

Risk of electric shock and risk of fire due to insufficient overcurrent protection devices

In order to avoid the risk of fire or electric shock, overcurrent protection devices should be

dimensioned so that, when a fault occurs, the equipment is switched off sufficiently quickly.

Measurements must be taken at the installation site to determine whether the short-circuit

current is sufficient to trip the protective devices quickly enough. Not only must the loop

impedance be measured and the expected short-circuit current calculated, but the time-

current characteristics of the overcurrent protection devices must also be compared, using

measuring instruments in accordance with EN 61557-3.

If the necessary break times are not maintained, then the next smallest overcurrent

protection devices must be used. Under no circumstances may fuses with a higher rated

current ln than specified be used.

Note

The devices can be connected to supply systems of up to 480 VAC, which can supply a

maximum of 65 kA symmetrically ("prospective current" according to EN 60269-1).

6.3

Line Contactor Control

The line contactor is used for the electrical isolation of the drive group and the DC link from

the energy supply system.

When selecting a line contactor, the characteristic values in the technical data apply. The

cable routing, the bundling factor, and the factor for the ambient temperature according to

EN 60204-1 must be taken into account when dimensioning the various cables.

CAUTION

Line contactors must not be switched under load.

Note

To limit the switching overvoltage, the contactor coil must be connected to a surge

suppression device (e.g. freewheeling diode or varistor).

When the digital output is used to control the line contactor, its switching capacity must be

taken into account.

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6.3 Line Contactor Control

6.3.1

Line contactor control for Line Modules without DRIVE-CLiQ interface (5 kW

and 10 kW versions)

If a line contactor is required for Line Modules without DRIVE-CLiQ interface, it must be

controlled and monitored using an external controller.

NOTICE

Device damage due to incorrect activation or deactivation sequence

The line contactor or Line Module may be destroyed if an incorrect activation or

deactivation sequence is used.

• When controlling the line contactor, make sure that switching of it is largely load-free.

• It is essential that you adhere to the following specifications for activation and

deactivation:

Activation:

Once the line contactor has been activated and a feedback is present, the pulse enable

(Enable Pulses) of the -X21:3/4 terminal can be made.

Deactivation:

Deactivation of the line contactor (LC) may only be carried out in a specific timing for the

pulse enable (Enable Pulses) (-X21:3/4) and/or Ready (-X21:1) signals.

● Pulse enable (EP):

A deactivation of the line contactor may only be made when the pulse enable (EP) signal

has been removed previously (t ≥ 10 ms). The current is removed during the delay time.

● Ready:

When the ready message leaves the SLM, the line contactor may only, if required, be

deactivated after a delay time (t ≥ 10 ms). The current is removed during the delay time.

Figure 6-7

Line contactor control signal chart

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6.3 Line Contactor Control

① Safety control

② Pulse enable

③ Ready

④ Prewarning

⑤ Reset

The numbers in brackets (3), (0), (2) refer to the numbers in the previous graphic.

Figure 6-8

Line Contactor Control for Smart Line Module without DRIVE-CLiQ

Note

If the line contactor should also be safely disconnected (safety), the control must be

integrated in an existing safety control. This is the only way to ensure the line contactor is

switched in accordance with the required safety categories; see also the chapter titled

Safety Integrated (Page 483).

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6.3 Line Contactor Control

6.3.2

Line Contactor Control for Line Modules with DRIVE-CLiQ Interface

Line Modules with DRIVE-CLiQ interface can control an external line contactor. The closing

and opening of the line contactor can be monitored by evaluating the feedback contact of the

line contactor. This control ensures that the line contactor always switches in a defined

manner and so prevents overloading or damaging the line contactor and/or the infeed.

The line contactor can be controlled using the r0863.1 bit of the INFEED drive object (for

840D sl and 16 kW to 120 kW Line Module).

Note

For further information about the line contactor, refer to the device manuals.

Note

If the line contactor should also be safely disconnected (safety), the control must be

integrated in an existing safety control. This is required so that the line contactor is switched

in accordance with the required safety categories. See also Section Safety Integrated

(Page 483).

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6.3 Line Contactor Control

6.3.3

Line Contactor Control Commissioning using an Example

Assumption:

● Line contactor control uses a digital output of the Control Unit (DI/DO 14)

● Line contactor feedback uses a digital input of the Control Unit (DI/DO 7)

● Line contactor switching time is less than 100 ms

Note

The parameter assignment for interface X132 at pins 4 and 12 must be changed using

the "SINUMERIK Operate" drive commissioning wizard.

Figure 6-9

Line Contactor Control

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6.3 Line Contactor Control

Commissioning steps:

Note

If the current carrying capacity of the digital output may be exceeded, an auxiliary contactor

must be used (refer to the Booksize Power Units Equipment Manual).

1. Connect control contact of the line contactor to DI/DO 14.

2. Parameterize DI/DO 14 as output (p0728.14 = 1).

3. Interconnect (BI: p0744 = r0863.1 of NCU) DI/DO 14 with "control contactor" signal

(r0863.1 of infeed).

4. Connect the feedback contact of the line contactor to DI 7.

5. Interconnect (BI: p0860 = r0722.7) p0860 with inverted input signal (p0722.7).

6. Enter the monitoring time of the line contactor (p0861 = 100 ms).

Function diagram overview

●

8934 missing enables, line contactor control

Parameter overview

● r0863.1 CO/BO: Drive coupling status word/control word

● p0860 BI: Line contactor feedback

References

/LH1/SINAMICS S120/S150 List Manual

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6.4 Line filters

6.4

Line filters

6.4.1

Safety instructions for line filters

Note

When using a line filter, also observe the safety instructions in Section 1.

CAUTION

Risk of burns due to high surface temperatures

The line filter can become very hot. You can get seriously burnt when touching the surface.

• Mount the line filter so that contact is not possible. If this is not possible, attach a clearly

visible and understandable warning notice at hazardous positions.

• To prevent adjacent components from suffering damage due to these high

temperatures, maintain a clearance of 100 mm on all sides of the line filter.

NOTICE

Line filter damage by connecting to impermissible line supplies

Line filters are only suitable for direct connection to TN line supplies.

NOTICE

Line filter damage due to interchanged connections

The input and output connections/terminals must not be interchanged:

• Incoming line cable to LINE L1, L2, L3, and

• Outgoing line to line reactor at LOAD L1´, L2´, L3´ (U, V, W).

The line filter may be damaged if this is not observed.

WARNING

Fire hazard due to overheating because of inadequate ventilation clearances

Inadequate ventilation clearances cause overheating with a risk for personnel through

smoke development and fire. Damage can still occur on the line filter.

• For this reason, maintain the 100 mm clearances above and below the line filter.

NOTICE

Using an incorrect line filter

Line filters may only be used in combination with the components listed in Section

"Possible line reactor and line filter combinations".

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6.4 Line filters

NOTICE

Damage or destruction of additional loads as a result of undesirable line harmonics

Only the line filters described in this manual must be used. Other line filters can cause line

harmonics that can interfere with or damage other loads fed from the line supply.

NOTICE

Damage or destruction of additional loads by connecting after the line filter

The associated Line Module must only be connected to the SINAMICS line filter via the

associated line reactor. Additional loads must be connected upstream of the SINAMICS line

filter (if required, via a separate line filter). If this is not observed, other loads could be

damaged or destroyed.

Note

Disconnect the line filter for a high-voltage test

If a high-voltage test is conducted with alternating voltage in the system, the existing line

filters must be disconnected in order to obtain accurate measurements.

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6.4 Line filters

6.4.2

Overview of line filters

Used in conjunction with line reactors and a consistent EMC-compliant system configuration,

line filters limit the conducted electromagnetic emissions generated by the Line Modules to

limit values that conform to EN 61800-3. For the SINAMICS S120 drive line-up, a separate

line filter must be used on the basis of the table below.

Note

Avoid mutual interference of multiple line filters

An additional line filter must be used to suppress interference in other loads. To prevent

mutual interference, this line filter must not be equipped with line-side capacitors with respect

to ground. Filter series B84144A*R120 (EPCOS) is recommended.

Note

According to product standard EN 61800-3, RFI suppression commensurate with the

relevant rated conditions must be provided and is a legal requirement in the EU (EMC

Directive). Line filters and line reactors are required in order to comply with this standard.

The use of filters of other makes can lead to limit value violations, resonances, overvoltages,

and irreparable damage to motors or other equipment. The machine manufacturer must

provide verification that the machinery to be operated with the drive products and the

installed suppression elements, e.g. line filters, are CE/EMC-compliant before the machines

are approved for delivery.

Line filter ranges that are coordinated with the different power stages are available for the

SINAMICS S120 drive system. These line filters differ with regard to the frequency range in

which they reduce the conducted emissions.

The line filter versions listed below are available for use with Line Modules.

Table 6- 3

Overview of line filters

Order number

Basic Line Filter for Active Line Modules with line reactor

16 kW

6SL3000-0BE21-6DAx

36 kW

6SL3000-0BE23-6DA1

55 kW

6SL3000-0BE25-5DAx

Basic Line Filter for Active Line Modules with Active Interface Modules

16 kW

6SL3000-0BE21-6DAx

36 kW

6SL3000-0BE23-6DA1

55 kW

6SL3000-0BE25-5DAx

80 kW

6SL3000-0BE28-0DAx

120 kW

6SL3000-0BE31-2DAx

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6.4 Line filters

Order number

Wideband Line Filter for Active Line Modules

16 kW

6SL3000-0BE21-6AAx

36 kW

6SL3000-0BE23-6AAx

55 kW

6SL3000-0BE25-5AAx

80 kW

6SL3000-0BE28-0AAx

120 kW

6SL3000-0BE31-2AAx

Basic Line Filter for Smart Line Modules

5 kW

6SL3000-0HE15-0AAx

10 kW

6SL3000-0HE21-0AAx

16 kW

6SL3000-0BE21-6DAx

36 kW

6SL3000-0BE23-6DA1

55 kW

6SL3000-0BE25-5DAx

6.4.3

Wideband Filter for Active Line Modules

Wideband Line Filters for Active Line Modules are mainly effective in the frequency range

from 150 kHz to 30 MHz; this is the range relevant to ensure compliance with the appropriate

standard. Wideband Line Filters can also effectively limit low-frequency line harmonics of

2 kHz and above; this protects additional loads connected to the same supply system

against disturbances and damage. As a result, these line filters have an extended function

area, which means that they can, to a certain extent, be used regardless of the machine

installation location and any unknown line properties (e.g. line impedance).

Wideband Line Filters must always be used in conjunction with an HFD line reactor for

Active Line Modules and not with an Active Interface Module.

Wideband Line Filters for Active Line Modules can achieve the interference voltage

categories listed below, when used in conjunction with the associated HFD line reactor and

an EMC-compliant design (see also the chapter titled "Combination options: Line reactors

and line filters"):

● EN 61800-3 category C2 up to a total cable length ¹⁾ of 350 m (shielded) for 16 kW,

36 kW, 55 kW, 80 kW, and 120 kW components

● EN 61800-3 category C3 up to a total cable length ¹⁾ of 350 m (shielded) for 16 kW,

36 kW, 55 kW, 80 kW, and 120 kW components

¹⁾Maximum total cable length = Σ motor cables, line supply conductor from line filter to Line

Module

Note

Further information

For more detailed information on Wideband Line Filters, refer to the SINAMICS S120

Booksize Power Units Equipment Manual.

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6.4 Line filters

6.4.4

Basic Line Filters for Active Line Modules

Basic Line Filters for Active Line Modules are designed to attenuate conducted interference

emissions in accordance with the specifications contained in the relevant EMC legislation.

They are mainly effective in the frequency range from 150 kHz to 30 MHz; this is the range

relevant to ensure compliance with the appropriate standard.

Basic Line Filters can be used in conjunction with a line reactor for 16 kW, 36 kW, and

55 kW Active Line Modules or with an Active Interface Module for 16 kW, 36 kW, 55 kW,

80 kW, and 120 kW Active Line Modules. Assuming that an EMC-compatible design is used,

the interference voltage categories listed below will be achieved (see also the chapter titled

"Combination options: Line reactors and line filters").

Basic Line Filter for Active Line Modules and line reactor

● EN 61800-3 category C2 up to a total cable length ¹⁾ of 150 m (shielded) for 16 kW,

36 kW, and 55 kW components

● EN 61800-3 category C3 up to a total cable length ¹⁾ of 150 m (shielded) for 16 kW,

36 kW, and 55 kW components

Basic Line Filters for Active Line Modules and Active Interface Module

● EN 61800-3 category C2 up to a total cable length ¹⁾ of 350 m (shielded) for 16 kW,

36 kW, 55 kW, 80 kW, and 120 kW components

● EN 61800-3, category C3, up to a total cable length ¹⁾ of

630 m (shielded) for 16 kW and 36 kW components

–

1000 m (shielded) for 55 kW, 80 kW and 120 kW components.

¹⁾Maximum total cable length = Σ motor cables, line supply conductor from line filter to Line

Module

The Basic Line Filters can be used in accordance with the following general conditions for

ensuring CE conformity with regard to cable-borne interference:

● The machine/system must only be used in industrial power systems

● Only connect the Basic Line Filters to TN systems; otherwise, an isolation transformer will

be required

● Number of axes ≤ 12 when using a Basic Line Filter with an Active Line Module and a line

reactor

Note

Basic Line Filters for Active Line Modules with line reactor must be approved (incurs a fee).

Note

Further information

For more detailed information on Basic Line Filters, refer to the SINAMICS S120 Booksize

Power Units Equipment Manual.

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6.4 Line filters

6.4.5

Basic Line Filter for Smart Line Modules

Basic Line Filters for Smart Line Modules are designed to attenuate conducted interference

emissions in accordance with the specifications contained in the relevant EMC legislation.

They are mainly effective in the frequency range from 150 kHz to 30 MHz; this is the range

relevant to ensure compliance with the appropriate standard.

Basic Line Filters for Smart Line Modules can achieve the interference voltage categories

listed below, when used in conjunction with the associated line reactors and an EMC-

compliant design (see also the chapter titled "Combination options: Line reactors and line

filters"):

● EN 61800-3 category C2 up to a total cable length ¹⁾ of 350 m (shielded) for 5 kW to

55 kW components

● EN 61800-3 category C3 up to a total cable length ¹⁾ of 350 m (shielded) for 5 kW to

55 kW components

Basic Line Filters are only suitable for direct connection to TN systems. An isolation

transformer is required for other systems.

¹⁾Maximum total cable length = Σ motor cables, line supply conductor from line filter to Line

Module

Note

Further information

For more detailed information on Basic Line Filters, refer to the SINAMICS S120 Booksize

Power Units Equipment Manual.

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6.5 Active Interface Module (AIM)

6.5

Active Interface Module (AIM)

6.5.1

Description

Active Interface Modules are line-side interfaces for the Active Line Modules.

They contain the following functional units:

● Line reactor

● Low-frequency/switching frequency filters

● Line filter to EN61800-3, category C3, max. total motor cable length 350 m (shielded)

● Reduction of the stress on the motor insulation from system-dependent resonance factors

In conjunction with an Active Line Module and an EMC-compliant configuration the following

radio interference voltage categories are achieved:

● EN 61800-3 category C3 without an additional line filter up to a total cable length of

350 m (shielded) for 16 kW, 36 kW, 55 kW, 80 kW and 120 kW components

● EN 61800-3 category C2 with an additional Basic Line Filter up to a total cable length of

350 m (shielded) for 16 kW, 36 kW, 55 kW, 80 kW and 120 kW components

● EN 61800-3, category C3, with an additional Basic Line Filter up to a total cable length of

630 m (shielded) for 16 kW and 36 kW components

1000 m (shielded) for 55 kW, 80 kW, and 120 kW components

The Active Interface Module is fitted with a fan. The 24 V supply is essential for operating the

component. Connection of the temperature signaling contact to the Active Line Module is

also required.

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6.5 Active Interface Module (AIM)

6.5.2

Safety instructions for Active Interface Modules

Note

When using an Active Interface Module, also observe the safety instructions in Section 1.

NOTICE

Destruction of the Active Interface Module through incorrect settings made during

commissioning

The Active Interface Module can be destroyed through incorrect settings in the software.

Operate Active Interface Modules only with the following settings in the commissioning

wizard:

• Set the "Line filter available" option for the Active Line Module.

• Select line filter "AIM 400 V xxkW (6SL3100-0BE**-*AB*)"

In conjunction with SINAMICS V2.6, the appropriate Active Interface Module is already

preset by running the wizard in STARTER.

With firmware version SINAMICS V2.5, the default setting in STARTER/SCOUT is

"Wideband Line Filter". Parameter p0220 must be changed to "AIM".

Operation with a SINAMICS firmware less than V2.5 is not permitted.

NOTICE

Destruction of the Active Interface Module through incorrect/missing wiring

The Active Interface Module can be destroyed through incorrect wiring or a missing 24 V

supply.

• Before commissioning the Active Interface Module, it is essential to connect the 24 V

DC at connector X124 to supply the fans. Current required ≤ 1.2 A.

• Connect the temperature signaling contact of the Active Interface Module to the

temperature input of the associated Active Line Module.

CAUTION

Risk of burns due to high surface temperatures

The Active Interface Module can become very hot. You can get seriously burnt when

touching the surface.

• Mount the Active Interface Module so that contact is not possible. If this is not possible,

attach a clearly visible and understandable warning notice at hazardous positions.

• To prevent adjacent components from suffering damage due to these high

temperatures, maintain a clearance of 100 mm on all sides of the Active Interface

Module.

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6.5 Active Interface Module (AIM)

WARNING

Fire hazard due to overheating because of inadequate ventilation clearances

Inadequate ventilation clearances cause overheating with a risk for personnel through

smoke development and fire. Damage can still occur on the Active Interface Module.

• Maintain the 80 mm clearances above and below the Active Interface Module.

NOTICE

Permitted mounting position

The Active Interface Modules must only be operated when mounted in a vertical position

("hanging").

NOTICE

Connection cables

The connection cables between the Active Interface Module and the Active Line Module, as

well as between the Active Interface Module and the Basic Line Filter, must be kept as

short as possible (max. 10 m in total).

Shielded connection cables must be used in order to achieve interference voltage category

C2. The cable shields must be connected on both sides.

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6.5 Active Interface Module (AIM)

6.5.3.2

Line/load connection

Table 6- 4

Line and load connection Active Interface Module

6SL3100-0BE21-

6SL3100-0BE23-

6SL3100-0BE25-

6SL3100-0BE28-

6SL3100-0BE31-

6ABx

5ABx

0ABx

2ABx

Power

16 kW

36 kW

55 kW

80 kW

120 kW

Line supply

Connector, 16

Screw terminal

Threaded bolt M8,

connection

mm²

50 mm², end

cross-section 120 / 2 x 50 mm²,

L1, L2, L3

sleeve,

1.7 Nm

13 Nm¹⁾

Load connection

6 Nm

U2, V2, W2

1) For ring cable lugs in accordance with DIN 46234

Note

The connection terminals of the 36 kW and 55 kW Active Interface Modules are only certain

to be safe from touch protection according to EN 60529 if cables with a minimum cross-

section of 25 mm² and insulated end sleeve are used.

6.5.3.3

X121 temperature sensor and fan control

Table 6- 5

Plug-in screw terminal X121

Terminal

Designation

Technical specifications

+Temp

Output temperature switch

Must be connected to X21 of the Active Line Module

-Temp

Temperature switch output

+24 V power supply for digital

Current carrying capacity: 500 mA

inputs

Disable Fan

The fan can be disabled. The fan may only be switched

off while the Active Line Module is disabled.

Max. connectable cross-section: 1.5 mm²

Note

If the terminals are not connected (or connected with low level), the fan will run in continuous

mode.

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6.5 Active Interface Module (AIM)

6.5.3.4

Electronics power supply X124

Table 6- 6

Terminal block X124

Terminal

Function

Technical specifications

Electronics power supply

Voltage: 24 VDC (20.4 V - 28.8 V)

Electronics power supply

Current consumption: max. 1.6 A

Electronics ground

Max. current via jumper in connector:

20 A at 55 °C

Electronics ground

Max. connectable cross-section: 2.5 mm²

Note

The two "+" or "M" terminals are jumpered in the connector. This ensures the supply voltage

is looped through.

6.5.4

Operation on an isolated-neutral system (IT system)

6.5.4.1

IT systems

In IT systems, all live parts are isolated from ground, or one point is connected to ground

through an impedance. The exposed conductive parts of the electrical installation are either

grounded separately or grounded together, or jointly connected to the system ground.

Only Line Modules without a line filter are to be operated on this system type. The emitted

interference can exceed the limit values of category C3. The Active Interface Module must

be set for operation on an IT system.

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6.5 Active Interface Module (AIM)

6.5.4.2

Operating an Active Interface Module on an isolated-neutral line supply (IT line supply)

Note

When an Active Interface Module is operated in an isolated-neutral line supply (IT line

supply), the connection bracket for the interference suppression capacitor in the AIM must

be removed. The connection bracket for the interference-suppression capacitor is located on

the lower side of the component.

If the connection bracket for the interference-suppression capacitor is not removed, an

insulated supply will be grounded and may cause tripping of the isolation monitor in the case

of failure.

There are no limits of interference for isolated-neutral systems. Removing the connection

bracket to the interference-suppression capacitor eliminates the effect of the filter against

ground. It nevertheless makes sense to install an Active Interface Module because the clock

frequency filter is still active and also protects other loads on the same network from clock

frequency disturbances.

DANGER

De-energize the device before removing the connection bracket

The connecting bracket may only be removed in the de-energized state.

Risk of electric shock. A hazardous voltage is still present for up to five minutes after the

power supply has been switched off.

Remove the connection bracket for the

Remove the connection bracket.

Connection bracket for the

interference-suppression capacitor with

interference-suppression capacitor

a Tx25 screwdriver.

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SINUMERIK 840D sl. Service - Configuring Commissioning. Manual (2011-2020) - page 29