System components overview in SINAMICS power modules

System components / Modules in the power section
Training objectives:
You are informed about
• the electrical design of the

powermodules
• the options for 4Q-operation
• the components for the modular

design of the device types:
- Booksize
- Chassis / Cabinet segments
• overload capability, cable lengths

and attainable output voltage
SINAMICS Date:
File:
06/03/2007
ABU DHABI: Page 2 - 1
SITRAIN Training for
Automation and Drives
Siemens AG 2007. All rights reserved.
System components / Modules in the power section

Content Page
Component overview, example SINAMICS S120............................................................................. 3
Motor Module (Combination Booksize/Chassis possible on same CU320)........................................ 4
Electrical design of the power modules............................................................................................. 5
Pulse frequency / Active Line Module, Motor Module........................................................................ 6
Overview of infeed units................................................................................................................... 7
Electrical design of the power module S150..................................................................................... 8
Active Line Module / Circuit design: Chassis.................................................................................... 9
Electrical design of the power modules G130, G150......................................................................... 10
Basic Line Module / Circuit design: Chassis..................................................................................... 11
Smart Line Module / Circuit design: Chassis..................................................................................... 12
DC-link components......................................................................................................................... 13
DC-link components......................................................................................................................... 14
DC-link connection........................................................................................................................... 15
Electronic draw-out unit for chassis / Cabinet................................................................................... 16
Current actual value sensing / Thermal model.................................................................................. 17
System components on the motor-side............................................................................................. 18
Overload capability of Booksize-units............................................................................................... 19
Overload capability of Chassis-units................................................................................................. 20
Multi-parallel operation of converters S120 / AIM,ALM + MoMo........................................................ 21
Cable lengths................................................................................................................................... 22
Overall cable lengths of Booksize-units (per motor).......................................................................... 23
Attainable output voltage.................................................................................................................. 24
SINAMICS Date:
File:
06/03/2007
Component overview, example SINAMICS S120
• SINAMICS S120 solves

complex drive tasks for a
large range of industrial
applications and is
therefore designed as a
modular system.
• The user can choose from

many harmonized
components and functions
to create a solution that
best meets his
requirements.
SINAMICS Date:
File:
06/03/2007
Motor Module (Combination Booksize/Chassis possible on same CU320)

Booksize Booksize Chassis 400V Chassis 690V
Single MM Double MM
1.6 – 107 kW 2x1.6 – 2x9.7 kW 110 – 1405 kW 85 – 1270 kW
Booksize / special features FS F FS G FS H FS J

Diagnostic LEDs
short circuit and earth fault proof sine filter dv/dt filter; VPL1 choke
integrated safety functions “Safe 90-200 kW (400V/4kHz/SVM) 75-1200 kW 75-1200 kW
standstill” and ”Safe brake control“
integrated motor brake control
(up to 132 A)
1 Voltage Peak Limiter
SINAMICS Date:
File:
06/03/2007
Electrical design of the power modules
U, f = constant U, f = variable
U Udc U
AC - DC DC - AC
i.e. 3AC, 400V, 50 Hz depending on line voltage or controlled
Rectifier DC-link Inverter
U1 U2
V1 V2
W1 W2
depending on line module
M
Line Line Module DC-link Motor Module Motor
SINAMICS Date:
File:
06/03/2007
Pulse frequency / Active Line Module, Motor Module
2 kHz --> 500 µs
Pulse width modulation / Active Line Module Pulse width modulation / Motor Module
Framesize Switching frequency Switching frequency Current contr.

Active Line Module Motor Module sample time
s
losse
F, G (400V) 4.0 kHz 2.0 kHz (.... 8.0 kHz) 250 μs hing
Switc forma
nce
F, G (690V) 4.0 kHz 1.25 kHz (.... 5.0 kHz) 400 μs
am ic per
Dyn
H, J (400V) 2.0 / 4.0 kHz 1.25 kHz (.... 5.0 kHz) 400 μs
1,25 pulse frequency (kHz) 8
Booksize 8.0 kHz 2.5 / 4.0 kHz (.... 16 kHz) 400 / 250 μs
SINAMICS Date:
File:
06/03/2007
Overview of infeed units
Active • Active Interface Module (AIM)

Infeed = • Active Line Module (ALM)
Actively controlled IGBT rectifier
Infeed
Infeed Smart • Line connection with choke
AC
AC // DC
DC Infeed = • Smart Line Module (SLM)
Line commutated IGBT rectifier
Basic • Line connection with choke

= • Basic Line Module (BLM)
Infeed
Line commutated B6-circuit rectifier
Properties Basic Infeed Smart Infeed Active Infeed

Operating mode 1Q operation / 4Q operation, 4Q operation,
uncontrolled uncontrolled controlled
Line supply fluctuations influence V_DC influence V_DC are compensated
Line feedback no yes yes
Harmonics to be considered to be considered can be neglected
Reactive power compens. no no yes
available for G130, G150 S150
S120 (type-depending) S120 (type-depending) S120 (type-depending)
SINAMICS Date:
File:
06/03/2007
Electrical design of the power module S150
U Udc U
AC - DC DC - AC
i.e. 3AC, 400V, 50 Hz controlled to setpoint voltage
Pre-charging Rectifier DC-link Inverter
U1 U2
V1 V2
W1 W2
Line Motor
DC-link
SINAMICS Date:
File:
06/03/2007
Active Line Module / Circuit design: Chassis
Main features: Booksize Chassis 400 / 690 V

Controlled rectifying / regenerating 16 - 120 kW 132-900 / 560-1400 kW
unit with IGBT technology
Unrestricted regenerative operation Power block with
Boost operation enables controlled IGBT‘s, DC caps
DC-link voltage and sinusoidal line
Current transformer
current
Power factor control to obtain Electronic draw-out
cos φ = 1 unit CIB, CU320
Fan
FS J
SINAMICS Date:
File:
06/03/2007
Electrical design of the power modules G130, G150
U Udc U
AC - DC DC - AC
constant
i.e. 3AC, 400V, 50 Hz appr. 1,35 * 400V = 540V DC
Pre-charging Rectifier DC-link Inverter
RVL
U1 U2
V1 V2
W1 W2
RVL
Line Motor
DC-link Braking Chopper
SINAMICS Date:
File:
06/03/2007
Basic Line Module / Circuit design: Chassis

Line commutated rectifier unit under prep. 200-710 / 250-1100 kW
with thyristor technology
(B6 circuit) Thyristors and
No line feedback possible Thyristor control
Power block
S120 chassis and cabinet
segments with pre-charging by Slot for CU320,
means of firing angle control. electronic draw-out unit
Fan
S120 Booksize and G130/G150
with pre-charging via diode rectifier Fan fuses
and pre-charging resistors. FS G
SINAMICS Date:
File:
06/03/2007
Smart Line Module / Circuit design: Chassis
Line supply Smart Line Module

DC+
T1 D1 T2 D2 T3 D3
LN LN
u1
LN LN
u2 Cd
LN LN
u3
EMC basic suppression
(for T4 T5 T6
D4 D5 D6
3 AC bypass contactor
380-690V precharging DC-
50/60Hz line choke
line fuses)
Line connection

Uncontrolled rectifying / 5, 10 kW 140-800 / 132-1400 kW
regenerating unit with IGBT
technology Power block with
The use of IGBT modules IGBTs, DC-capacitors
prevents commutation failure as Current transformer
consequence of line supply failure
Electronic draw-out unit
CIB, CU320
Fan
FS H from 06/2006
SINAMICS Date:
File:
06/03/2007
DC-link components
Braking Module and Braking resistors

Module operates autonomously
When triggered, the DC-link energy is dissipated into heat via external braking
resistor.
Two braking resistors are available:
Booksize: 0,3 kW continuous braking power (25 kW peak braking power)
1,5 kW continuous braking power (100 kW peak braking power)
Chassis: 25 kW continuous braking power

(125 kW peak braking power)
50 kW continuous braking power
SINAMICS Date:
File:
06/03/2007
DC-link components
Braking Module and Braking resistors

Module operates autonomously
When triggered, the DC-link energy is dissipated into heat via external
braking resistor.
Two braking resistors are available:
Booksize:
0,3 kW continuous braking power
1,5 kW continuous braking power
Chassis:
Capacitor Module
Increases the DC-link capacity to cover up for short time line supply
interruptions and to better tolerate regenerative operation
Control Supply Module

Generates the 24 VDC supply from the line or from the DC-link voltage
SINAMICS Date:
File:
06/03/2007
DC-link connection
24V terminal adapter DC-connection

Direct DC-supply
24V
for chassis
DC-link
bus bar
2DC
Line Motor Motor

Module Module Module
Motor Module
DC connection for Chassis-units

3-stage isolator switch with two switch positions ( 0 / 1 )
0= Off isolator contacts are open
1= Pre charging pre charging resistor is switched on; pre
charging is completed after about 2.5 s
Operation with the on command for the Motor Module
the third switching position is automatically
activated
SINAMICS Date:
File:
06/03/2007
Electronic draw-out unit for chassis / Cabinet

Fib
re-o
ptic
3a Power-
2 supply
3
3b
3 DRIVE-CLiQ Base plate

sockets
1
3 Communication Interface board CIB

3a Adaptation Interface board AIBO (shunts, limit value monitoring)
3b Power Stack Adapter PSA (generation of the inverter pulse pattern)
Extended functionality of the CIB-FW starting with V2.3 and CIB-MLFB ...-3 (starting with HW-version M):
edge triggered modulation / safe stop / parallel operation of power sections up to 4xLM and 4xMM per CU320
SINAMICS Date:
File:
06/03/2007
Current actual value sensing / Thermal model
Current actual value sensing
Powerstacks of the SINAMICS Motor Modules

detect all three output phase currents
A fault current is detected through summation
(earth fault monitoring)
The current transformer (CT) calibration is
performed in the factory by means of shunt
resistors and powerstack data on the CIB
board.
Thermal model
The converter‘s thermal protection is activated when the rated current is exceeded
over a longer period of time or when the heat sink temperature becomes too high.
This leads to a failure shut down or to an automatic influence of the control (reduction
of pulse frequency or of current limit) to reduce the converter‘s thermal load.
SINAMICS Date:
File:
06/03/2007
System components on the motor-side
Motor reactors Limiting of capacitive charging-, discharging currents

Reduction of voltage gradient dv/dt
Typical uk about 1,5 %
For Motor Modules of power ratings 75 – 1200 kW
dv/dt – filter Limiting of voltage gradient to values < 500 V/µs

Limiting of phase-to-phase voltage to the value of the
DC-link voltage
Sine filter Provides near sinusoidal motor voltage

(voltage noise 5 – 7%)
Only for space vector modulation; in consequence only 90 %
motor voltage as compared to “no sine filter”
Required pulse frequency of the Motor Module: 4 kHz
For voltage range 660 – 690 V not available
SINAMICS Date:
File:
06/03/2007
Overload capability of Booksize-units
S1 operation with overload S6 duty cycle with base load
Catalogue D21.2 / chapter 2
duty cycle without base load
SINAMICS Date:
File:
06/03/2007
Overload capability of Chassis-units
Small overload at base load current IL High overload at base load current IH
150 % for 10 sec resp. 110 % for 60 sec 160 % for 10 sec resp. 150 % for 60 sec
Example
I L*150% ohne G1_kurz G1_lang G2_kurz G2_lang I *160%
H
(700A) Überlast 150% 110% 170% 150%
I_G, A 330 320 320 280 280I H*150%
Zeit_2, s 300 290 240 290 240
I_Max, A 0 480 352 476 420
Zeit_1, s 0 10 60 10 60
I L*110%
I_N, A 330 327 327 289 313
(500A)
I N_eff
IL
300 s 300 s IH
10 60 300 10 60 300 T [sec.]
without IL_short IL_long IH_short IH_long

overload 150% 110% 160% 150%
I_B, A 330 320 320 280 280
Values for IL and IH Time_2, s 300 290 240 290 240
taken from catalogue I_Max, A 0 480 352 448 420
Time_1, s 0 10 60 10 60
I_N, A 330 327 327 287 313
SINAMICS Date:
File:
06/03/2007
Multi-parallel operation of converters S120 / AIM,ALM + MoMo
Infeed units
Active Infeeds AIM+ALM
Decoupling Current balance control is
reactors provided
Symmetrical wiring of power
Infeed 1 Infeed 2 Infeed 4 Infeed units
cables is recommended
in parallel
Decoupling by means of
reactors of the Clean Power
Filter rsp. motor reactors
Control Current derating in parallel
Unit
CU320
CU320
operation (5% as compared
to a single unit ALM)
MoMo 1 MoMo 2 MoMo 4 Motor Modules MoMo

Motor modules Current balance control is
In parallel
provided
Decoupling
reactors
Motor connection
690V / 5600 kW
SINAMICS Date:
File:
06/03/2007
Cable lengths
DRIVE-CLiQ cables
Standard within the cabinet 70 m
MOTION-CONNECT 500 100 m
MOTION-CONNECT 800 50 m
Power cables Chassis / Cabinet

- Any combination
(without / with reactor; without / with sine-filter
without / with dv/dt-filter 1) )
screened 300 m (525 m) 2)
unscreened 450 m (785 m) 2)
Sensor cables
SMC10 - sensor: resolver 130 m for 2-pole resolvers:
50 m for multi pole resolvers:
SMC20 - sensor: Sin/Cos, absolute 100 m
SMC30 - sensor: HTL, TTL 100 m
HTL with A+/A- .. 300 m
1) with “dv/dt-filter + VPL” (Voltage Peak Limiter) as output filter
2) with two reactors in series; second reactor possible only outside the cabinet
SINAMICS Date:
File:
06/03/2007
Overall cable lengths of Booksize-units (per motor)
Cable length
50 m 100 m 150 m 200 m >=250 m
Rated
current
3A, 5A always allowed use 9A module
9A always allowed use 18A module
max. 150% Irated not allowed

18A always allowed (continuous max.
95% Irated) use 30A module
use 30A module
max. 135% Irated max. 110% Irated
always allowed always allowed (continuous max. (continuous max.
30A 90% Irated) 85% Irated) not allowed
45A, 60A 90% Irated) 85% Irated)
85A, 132A 95% Irated) 90% Irated)
200A 95% Irated) 90% Irated)
With Active Line Module and high efficiency line reactor: overall length of all power cables = 1000 m
SINAMICS Date:
File:
06/03/2007
Attainable output voltage
The maximum output voltage is defined by the DC-link voltage and the inverter modulation depth.
The DC-link voltage level depends on the Line Module used in the application.
For Basic Line Module and Smart Line Module and for G130/G150 :
V.DC = 1.32...1.41 * V.Line with p0210 = 380 – 480 VAC
For Active Line Module / Booksize :
V.DC = 600 VDC with p0210 = 380 – 400 VAC / Active Mode [V.DCÆp3510]
V.DC = 625 VDC with p0210 = 401 – 415 VAC / Active Mode [V.DCÆp3510]
V.DC = 1.32...1.41 * U.Line with p0210 = 416 – 480 VAC / Smart Mode
p3510 = 1.42 up to 2.0 * p0210
For Active Line Module / Chassis and for S150 :
V.DC = 1.5 * V.Line with p0210 = 380 – 480 VAC / p3510 = 1.42 up to 1.6 * p0210
The maximum modulation depth that can be set is defined by the “operation type” of the Motor Module.
For “operation type” Servo (S120 / only space vector modulation)
V.out max.rms = 0.67 * V.DC
For “operation type” Vector (S120, G150, S150 / space vector mod. and edge triggered mod.)
V.out max.rms = 0.72 * V.DC > FW V2.3 and CIB-MLFB ….-3 (HW-version > M)
SINAMICS Date:
File:
06/03/2007

System components overview in SINAMICS power modules

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System components overview in SINAMICS power modules

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System components / Modules in the power section

• the electrical design of the

• the options for 4Q-operation

• the components for the modular

• overload capability, cable lengths

System components / Modules in the power section

• SINAMICS S120 solves

• The user can choose from

Motor Module (Combination Booksize/Chassis possible on same CU320)

Booksize / special features FS F FS G FS H FS J

1 Voltage Peak Limiter

i.e. 3AC, 400V, 50 Hz depending on line voltage or controlled

Rectifier DC-link Inverter

Line Line Module DC-link Motor Module Motor

Pulse frequency / Active Line Module, Motor Module

2 kHz --> 500 µs

Framesize Switching frequency Switching frequency Current contr.

Active • Active Interface Module (AIM)

Basic • Line connection with choke

Properties Basic Infeed Smart Infeed Active Infeed

Electrical design of the power module S150

i.e. 3AC, 400V, 50 Hz controlled to setpoint voltage

Pre-charging Rectifier DC-link Inverter

Main features: Booksize Chassis 400 / 690 V

Electrical design of the power modules G130, G150

i.e. 3AC, 400V, 50 Hz appr. 1,35 * 400V = 540V DC

Pre-charging Rectifier DC-link Inverter

DC-link Braking Chopper

Main features: Booksize Chassis 400 / 690 V

Smart Line Module / Circuit design: Chassis

Line supply Smart Line Module

Main features: Booksize Chassis 400 / 690 V

Braking Module and Braking resistors

Chassis: 25 kW continuous braking power

Braking Module and Braking resistors

Control Supply Module

24V terminal adapter DC-connection

Line Motor Motor

DC connection for Chassis-units

Electronic draw-out unit for chassis / Cabinet

3 DRIVE-CLiQ Base plate

3 Communication Interface board CIB

Current actual value sensing

 Powerstacks of the SINAMICS Motor Modules

System components on the motor-side

Motor reactors  Limiting of capacitive charging-, discharging currents

dv/dt – filter  Limiting of voltage gradient to values < 500 V/µs

Sine filter  Provides near sinusoidal motor voltage

S1 operation with overload S6 duty cycle with base load

Catalogue D21.2 / chapter 2

duty cycle without base load

Overload capability of Chassis-units

10 60 300 10 60 300 T [sec.]

without IL_short IL_long IH_short IH_long

MoMo 1 MoMo 2 MoMo 4 Motor Modules MoMo

Power cables Chassis / Cabinet

max. 150% Irated not allowed

Attainable output voltage

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Powerstacks of the SINAMICS Motor Modules

Motor reactors Limiting of capacitive charging-, discharging currents

dv/dt – filter Limiting of voltage gradient to values < 500 V/µs

Sine filter Provides near sinusoidal motor voltage