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Sinamics

S150
Power Components

Siemens AG 2008 Subject to change without prior notice


Siemens AG 2007 Subject to change without prior notice

The SINAMICS S150 system


Overview power components

System
overview  Features, customer benefits
Technical data

Power
PowerCompon.
Block  Principle of the SINAMICS S150 with Active Infeed
Mechanical
system

Motors
 Infeed circuits

Options
 Active Infeed
General control

Closed-loop
control  Power modules
Tools Comiss.
Communication
 Service concept power components
Diagnostics
Application

Version: 19.11.2008 sin-g15-4-03-e.ppt I DT LD


Siemens AG 2007 Subject to change without prior notice

Power components
Features, customer benefits
Line
Connection Active Infeed
System Module Active
overview Interface
Module Active
Technical data
Line
Module
Power
PowerCompon.
Block Motor
Module
Mechanical
system SINAMICS S150
Motors Power Modules
Features Customer benefits
Options
Active Infeed  Regulated, stable DC link voltage
 High dynamic response using IGBT technology
General control
 Braking energy is regenerated into the line supply
Closed-loop  No inverter commutation faults
control  Reactive power compensation
 Can be operated on unstable line supplies
Tools Comiss.
Clean Power technology  Non-critical harmonics fed back into the supply for industrial
Communication environments

Diagnostics Integrated EMC filter for the second  Additional EMC filter is not required
environment  Compact solution
Application
Power Modules with standard,  Low-loss IGBT technology
modular design  High production quality, simple service concept
Version: 19.11.2008 sin-g15-4-03-e.ppt I DT LD
Siemens AG 2007 Subject to change without prior notice

Power components
Principle of the SINAMICS S150 with Active Infeed

System
The SINAMICS S150 converter cabinet comprises four basic modules
overview
Active Infeed Inverter
Technical data LCM AIM ALM MM

Power
PowerCompon.
Block AC / DC DC / AC

Mechanical
Line

system M
Motors

Options Vdc
DC - AC
U AC - DC U
General control

Closed-loop V, f = constant V = 0 400 V


control e.g. 3ph., 400V AC 1.5 * 400V = 600 V DC f = 0 300 Hz
Tools Comiss.
Communication
 Line Connection Module: Line connection, main breaker, fuses, EMC filter, 1st environment
Diagnostics  Active Interface Module: Pre-charging circuit with contactor, bypass contactor, line supply
Application voltage sensing, EMC filter, Clean Power Filter, step-up reactor, fan
 Active Line Module: Rectifier block, DC link capacitors, electronics module, fan, fuses
 Motor Module: Inverter block, DC link capacitors, electronics module, fan, fuses
Version: 19.11.2008 sin-g15-4-03-e.ppt I DT LD
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Power components
Positioning of various infeeds
Smart Infeed Active Infeed

Load operation
4Q operation 4Q operation
System S120 S150/S120
overview
Basic Infeed
Technical data 1Q operation
G150
Power
PowerCompon.
Block Performance
Mechanical Features Basic Infeed Smart Infeed Active Infeed
system Operating mode Non-regulated Non-regulated Regulated sinusoidal current
drawn from the line supply
Motors
Power electronics Thyristors IGBT IGBT
Options
Line fluctuations Are effective Are effective Are compensated

No Yes Yes
General control Regenerative feedback into the
line supply

Closed-loop
control Harmonics High High Non-critical

Inverter commutation faults --- No No


Tools Comiss.
Communication Reactive power compensation No No Yes

Diagnostics
Masterdrives EE ERE AFE
Application
For many applications, the additional cost for an Active Infeed pays-off a multiple number
of times.
Version: 19.11.2008 sin-g15-4-03-e.ppt I DT LD
Siemens AG 2007 Subject to change without prior notice

Power components
Infeed circuits: Basic Infeed
Line connection
Line supply

Line current
System
overview

Technical data
optional
(for breakers, fuses, EMC basic noise
Power
PowerCompon.
Block radio interference
suppression

suppression filter
etc.) VDC link1.35*V line supply
Mechanical
system
The SINAMICS Basic Infeed + Simple, rugged and favorably-priced
Motors  Is a line-commutated, non-regulated design
infeed unit utilizing thyristor technology
- Preferably 1-quadrant operation
Options (B6 circuit configuration).
- Braking energy is not regenerated into
 Mainly used in chassis units for
the line supply
General control 1-quadrant operation
- Braking chopper is required for
 Replaces the SIMOVERT
Closed-loop regenerative operation
MASTERDRIVES rectifier units
control - Line fluctuations must be taken into
account
Tools Comiss. - High harmonic component
RVL
Communication
Diagnostics Solution for SINAMICS G150/G130
Application
Pre-charging via diodes and resistors
RVL
(part of the AC-AC Power Module)
Version: 19.11.2008 sin-g15-4-03-e.ppt I DT LD
Siemens AG 2007 Subject to change without prior notice

Power components
Infeed circuits: Smart Infeed
Line
Line supply infeed

Line current
System
overview

Technical data
optional
Power
PowerCompon.
Block (for breakers,
fuses, radio EMC basic noise
interference suppression

Mechanical
suppression
filters etc.) VDC link1.35*V line supply
system
+ Optimized, simple and rugged design
The SINAMICS Smart Infeed
Motors + Capable of regenerating into the line
 Is a line-commutated, non-regulated
supply
infeed/regenerative feedback unit
Options + No inverter commutation faults even
utilizing IGBT technology.
when the power fails
 Replaces the SIMOVERT
General control + No auto transformer is required as for
MASTERDRIVES infeed/regenerative
ERE
Closed-loop feedback units.
control - No regulated DC link (line fluctuations
must be taken into account)
Tools Comiss. - Squarewave regenerative feedback into
Communication the line supply
- High harmonic component
Diagnostics - Pre-charging and bypass contactor
Application Planned for SINAMICS S150 required

Version: 19.11.2008 sin-g15-4-03-e.ppt I DT LD


Siemens AG 2007 Subject to change without prior notice

Power components
Infeed circuits: Active Infeed

Line connection
Line supply
Line current
System
overview

Technical data

optional
Power
PowerCompon.
Block (for breakers,
fuses, radio
interference EMC basic noise
Mechanical suppression
filters etc.)
suppression
VDC link=1.5*V line supply Bem
system
+ Regulated, stable DC link
The SINAMICS Active Infeed
Motors + Sinusoidal currents, also when regenerating
 Self-commutated, regulated
into the line supply
infeed/regenerative feedback unit
Options + Extremely low harmonics fed back into the
utilizing IGBT technology
line supply
 With Clean Power Filter
General control + Clean Power Filter for minimum distortion
 Replaces the SIMOVERT
factor
Closed-loop
MASTERDRIVES Active Front End
+ Reactive power compensation is possible
control + Highest degree of availability even for
Tools Comiss. unstable line supplies
+ No inverter commutation faults even when
Communication the power fails
Diagnostics - High price, noise
Application - Poor efficiency
Solution in SINAMICS S150 - Higher overall envelope dimensions
Version: 19.11.2008 sin-g15-4-03-e.ppt I DT LD
Siemens AG 2007 Subject to change without prior notice

Power components
Active Infeed: Features and customer benefits

Subject Solution Result

 Low-frequency harmonics  Sinusoidal current is drawn from  For industry, non-critical harmonics are fed back into
System
fed back into the line the line supply the line supply
overview supply, <9kHz  Clean Power Filter in the AIM with  Optimum protection against transient switching spikes
 (harmonics) new design
Technical data

Power Block  Harmonics fed back into


PowerCompon.  Integrated EMC filter for the 2nd EMC filter is not required for the 2nd
 Additional
the line supply >9kHz, environment environment (industry)
(EMC)
Mechanical
system  Unstable line supplies  Regulated DC link voltage  Highest degree of availability even for unstable line
supplies (V/frequency fluctuations)
Motors
 Reactive power  A reactive current can be  In the factory setting, there is no reactive power (cos =
optionally impressed 1).
Options
 An additional reactive power compensation system to
reduce power costs is not required
General control
 Operational reliability  Self-commutated IGBT  No inverter commutation faults when fuses fail during
infeed/regenerative feedback unit regenerative feedback
Closed-loop
 UCE monitoring  The unit can be quickly isolated from the line supply
control
 Thermal model monitors the  Brief line supply dips are buffered single-phase line
power semiconductors dips can be tolerated
Tools Comiss.
 Extensive range of monitoring functions
Communication
Diagnostics  Control quality  Regulated (closed-loop  High closed-loop dynamic response for fast load
controlled) DC link voltage, de- changes
Application coupled from the line supply  100% Va for rated motor values
characteristics
 Stable motor voltage for stall protection
Version: 19.11.2008 sin-g15-4-03-e.ppt  V DC link without harmonics, torque I DT LD
Siemens AG 2007 Subject to change without prior notice

Power components
Active Infeed: Infeed and stepping-up

Simplified principle of operation:


VDC link=1.5 Vn
System 1. 2 line phases are short-circuited.
overview
2. The short-circuit current is limited by the
VU-V step-up reactors.
Technical data
3. At the same time, the magnetic field of
Power
PowerCompon.
Block the reactor acts as energy-storage
device.
Mechanical
system
4. The short-circuit is interrupted.
Motors 5. High self-induction voltage because the
current at the reactor changes quickly
Options Vind= di/dt 6. The self-induction voltage is added to the
VU-V instantaneous line supply voltage. The
General control sum of the two voltages exceeds the DC
link voltage.
Closed-loop 7. Current flows in the DC link.
control 8. The whole sequence repeats after
Tools Comiss. approx. 250 s (4 kHz clock cycle
frequency)
Communication
Diagnostics
At infeed, the Active Line Module acts, in principle just like a Motor Module in the
Application
regenerative mode. The line supply is connected instead of a motor.
The main current flow for infeed
Version: 19.11.2008
operation is realized via the free-wheeling diodes.
sin-g15-4-03-e.ppt I DT LD
Siemens AG 2007 Subject to change without prior notice

Power components
Active Infeed: Regenerative feedback

Simplified principle of operation:


System VDC link=1.5 Vn
overview 1. The DC link voltage is higher than the
line supply voltage at each instant in
Technical data VU-V time.
2. The positive and negative busbars are
Power
PowerCompon.
Block connected to the appropriate line phase
Mechanical by turning-on two transistors.
system 3. Energy flows back into the line supply.

Motors
4. In order to achieve controlled
Options regenerative feedback, a transistor is
turned-off.
General control 5. The step-up reactor continues to drive
the current and a free-wheeling circuit is
Closed-loop obtained through the opposite diode.
control
6. The sequence repeats itself after
Tools Comiss. approx. 250 s (clock cycle frequency 4
kHz)
Communication
Diagnostics
When regenerating into the line supply, in principle, the Active Line Module operates
Application
like a Motor Module when motoring.
The main
Version: current
19.11.2008 flow for infeed operation is realized via the free-wheeling diodes.
sin-g15-4-03-e.ppt I DT LD
Siemens AG 2007 Subject to change without prior notice

Power components
Active Infeed: Integrated EMC filter

Line supply
connection

System
overview

Technical data

Power
PowerCompon.
Block

Mechanical
system Clean-
optional
(for breakers, fuses, Power-
Motors radio interference
suppression filters
etc.)
Filter
EMC basic noise
Options suppression

EMC filter
General control
 SINAMICS S150 is equipped, as standard with an EMC filter, Category
Closed-loop C3 for industrial environments.
control
 When connected to non-grounded line supplies (IT), the radio
Tools Comiss. interference suppression filter should be de-activated by removing a
Communication metal bar (jumper).
Diagnostics
Application

Version: 19.11.2008 sin-g15-4-03-e.ppt I DT LD


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Power components
Active Infeed: Clean Power Filter
As a result of ALM switching operations as well its finite switching frequency,
harmonics are generated that pollute the line supply.
System For industrial line supplies (second environment according to EN 61800-3), these
overview must be limited to permissible and non-critical values using a line filter.
Technical data

Power
PowerCompon.
Block
3 AC
line supply
Mechanical
system New Clean Power Filter
 With a significantly more compact design
Motors  The line filter is designed so that the
compatibility level up to the 50th harmonic
Options and in the switching-frequency range of
2...9 kHz in rated operation is not
General control exceeded this means that the voltage 0.12%
level at the line supply connection point is Clean Power Technology
Closed-loop
control a maximum of 1% in the range of the 0.08%
switching frequency.
Tools Comiss. 0.04%
Communication
0.00%
Diagnostics 5. 7 11. 13 17. 19 23. 25
Application
A Clean Power Filter included as standard maintains the compatibility level at non-
critical
Version: values for industrial line
19.11.2008 supplies.
sin-g15-4-03-e.ppt I DT LD
Siemens AG 2007 Subject to change without prior notice

Power components
Active Interface Module: Mechanical design
FI GI HI JI

System
overview

Technical data

Power
PowerCompon.
Block

Mechanical
system

Motors

Options

General control

Closed-loop
control
Active Interface Modules include:
Tools Comiss.  Pre-charging circuit with contactor Active
Communication  Bypass contactor (only for AIM FS FI and FS GI) Interface
 Line supply voltage sensing module Module
Diagnostics  Clean Power Filter
Application  EMC filter (basic noise suppression)
 Step-up reactor
 Fan 19.11.2008
Version: sin-g15-4-03-e.ppt I DT LD
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Power components
Power Modules: Mechanical design
FX
GX HX JX
System
overview

Technical data

Power
PowerCompon.
Block

Mechanical
system

Motors

Options

General control

Closed-loop
control
Active
Tools Comiss. Motor
Line
Module
Communication Module
Diagnostics
Application The power modules essentially have the identical design for the Active Line Module
(ALM) and Motor Module (MM) they mainly comprise:
 Powerblock
Version: 19.11.2008 (power module), fan with transformer, electronics module, fuses. I DT LD
sin-g15-4-03-e.ppt
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Power components
Power Modules: Powerblock for ALM, MM
Features: IGD module,
 Latest IGBT technology IGBT
System  Low-inductance DC link busbars
overview CT
 Extremely compact packaging system
Technical data  Thermal model for a high degree of safety Heatsink

Power
PowerCompon.
Block Rectifier/inverter
Mechanical IGBT+ FL diodes
system IGD: Gating IGBT

nt
Heatsink

Fro
Motors
Balancing
CT
Options

DC
General control DC link
busbars
Capacitors
Closed-loop Braking chopper (option) DC link busbars
control
Capacitor battery
Tools Comiss. Power actuators include:
Communication  Active Line Module (ALM) as AC/DC power module
 Motor Module (MM) as DC/AC power module
Diagnostics The Powerblocks (power modules) which comprise the same hardware, for both
Application actuators differ as follows:
 MRPD, terminal/connection designations and data of the Powerblock (power module).
The different
Version: 19.11.2008functionality is established in the software.
sin-g15-4-03-e.ppt I DT LD
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Power components
Power Modules: Switching frequencies for ALM, MM
For the Active Infeed, the switching frequency must be optimized for the complete
system.
The ALM power modules can be optimized for line-side operation by using 60flat top
System
overview
space vector modulation (FT60 modulation):
 High switching frequencies to optimally dimension the line filter - and
Technical data  Fast power transfer using high ALM currents
Frame size Switching frequency Switching frequency
Power
PowerCompon.
Block
ALM (FT60) Motor Modules
Mechanical
system
FX, GX (400V) 4.0 kHz 2.0 kHz/4.0 kHz
Motors FX, GX (690V) 4.0 kHz 1.25 kHz/2.5 kHz
HX, JX (400/690V) 2.5 kHz 1.25 kHz/2.5 kHz
Options

General control

Closed-loop
control

Tools Comiss. Motor Modules are designed - according to coonditions on the motor side - for a
Communication
maximum permissible current and operate with a switching frequency of 2.0 (1.25) kHz,
with low losses.
Diagnostics The frequency should be reduced under certain conditions:
Application  Basic frequency 2.0 (1.25) kHz without derating
 Sinusoidal filter on the motor side: 4.0 (2.5 ) kHz  current derating!
 Output
Version: frequency up to 300 sin-g15-4-03-e.ppt
19.11.2008 Hz: 8.0 (5.0 ) kHz  current derating! I DT LD
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Power components
Power Modules: Electronics module

System
overview 3
Technical data

Power
PowerCompon.
Block

Mechanical
system 2
3
Motors

Options

General control

Closed-loop
control

Tools Comiss. 1
Communication Electronics module
Diagnostics
Application 1 Sheet steel panel (base plate)
2 Power Supply Board PSB
3Version:
Communication
19.11.2008 Interface board
sin-g15-4-03-e.pptCIB I DT LD
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Power components
Electronics: Voltage Sensing Module VSM

System
overview

Technical data

Power
PowerCompon.
Block Voltage Sensing Module VSM
 This is used to sense the line supply
Mechanical
system voltage
 Is part of the Active Interface Module and
Motors
connected to the closed-loop control via
DRIVE-CLiQ
Options
 The 24V DC power supply is taken from the
General control Line Connection Module
Closed-loop
control

Tools Comiss.
Communication
Diagnostics
Application

Version: 19.11.2008 sin-g15-4-03-e.ppt I DT LD


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Power components
Electronics: Control Unit CU320
DRIVE-CLiQ

System
overview

Technical data

Power
PowerCompon.
Block

Mechanical
system

Motors
VSM CIB CIB TM31
Options
Control Unit
CU320 Active Active
Motor
Interface Line
General control Module
Module Module
Closed-loop
control Both of the power modules (ALM and MM) are controlled from a control unit.
The connection to the control unit is estabalished via the internal DRIVE-CLiQ drive bus.
Tools Comiss. Additional components are connected to the CU320 via the CIBs of the ALM or of the
Communication MM and DRIVE-CLiQ :
 To the ALM: Voltage Sensor Module
Diagnostics  To the MM: Terminal Module, Sensor Module
Application All of the DRIVE-CLiQ components connected to the CU operate with their own
firmware that, when required, can be simply upgraded using the STARTER tool from the
CU320.
Version: 19.11.2008 sin-g15-4-03-e.ppt I DT LD
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Power components
Electronic rating plates with DRIVE-CLiQ
DRIVE-CLiQ:
 Control data is transferred in real time
System
 Diagnostics data and parameter values are sensed DRIVE-
overview CLiQ
 Error-tolerant data transfer protocol
Technical data  Automatic node detection
 Simple to handle using standardized connector system
Power
PowerCompon.
Block
Active Infeed Module Motor Module
Mechanical Order No., Order No.,
system Serial No., Serial No.,
rated power, rated current,
Motors ... ...

Options
Voltage Sensor Module Control Unit
General control Order No., Order No.,
Serial No., Serial No.,
... ...
Closed-loop
control

Tools Comiss.
Communication Terminal Module 1 Sensor Module
Order No., Order No.,
Diagnostics Serial No., Serial No.,
... ...
Application
DRIVE-CLiQ the real-time capable serial system interface of the SINAMICS family.
Electronic
Version: rating plates allow sin-g15-4-03-e.ppt
19.11.2008 auto-parameterization and avoid errors being made I DT LD
Siemens AG 2007 Subject to change without prior notice

Power components
Current actual value, thermal model

System
Current actual value sensing
overview
 SINAMICS S150 power modules sense
Technical data
all of the three phase currents at the output.
Power
PowerCompon.
Block
 The fault current is determined by summing
the currents (ground fault monitoring)
Mechanical  The CT (current transformer) is calibrated
system
in the factory using load resistors and power
Motors module data on the CIB.

Options

General control Thermal model


Closed-loop  .. simulates the temperature inside the IGBT module and
control when a critical value is exceeded, either results in a trip
Tools Comiss.
or the closed-loop control is automatically influenced
(depending on the situation, pulse frequency or output
Communication
current) so that the thermal load of the drive converter is
Diagnostics reduced.
Application

Version: 19.11.2008 sin-g15-4-03-e.ppt I DT LD


Siemens AG 2007 Subject to change without prior notice

Power components
Power module: Spare parts
The Power Module spare parts are:
System
overview
 DC fuses
Technical data

Power
PowerCompon.
Block  Power Blocks (power modules)
Mechanical
system
 Electronics module with
Motors Communication Interface Board CIB
Power Supply Board PSB
Options
 Control Unit
General control

Closed-loop  Fan and fan transformer


control

Tools Comiss.
The customer receives an individual list of spare parts
Communication
corresponding to the cabinet he ordered.
Diagnostics
Application Using a spare part tool for SINAMICS cabinet units, the
list can always be manually re-generated using the
Version: 19.11.2008
MRPD and Z options.
sin-g15-4-03-e.ppt I DT LD
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Power components
Power module: Instructions for replacement

System
overview

Technical data

Power
PowerCompon.
Block

Mechanical
system Example:
Removing the Powerblock
Motors FS G, approx. 15 min.

Options

General control

Closed-loop
control

Tools Comiss.
Communication
Diagnostics
Application
Main components can be simply replaced in the shortest time using clear
instructions.
Version: 19.11.2008 sin-g15-4-03-e.ppt I DT LD
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Power components
Replacing the Powerblock, fan and electronics (1)

System
overview

Technical data

Power
PowerCompon.
Block

Mechanical
system

Motors

Options

General control

Closed-loop
control

Tools Comiss. Control Unit and Every power block has


electronics module its own fan which can
Communication
are easily accessible. easily be replaced.
Diagnostics
Application rapid repair

Version: 19.11.2008 sin-g15-4-03-e.ppt I DT LD


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Exchange of CU320, Fan und Powerblock (1)

System The Powerblock can be completely replaced in the shortest time.


overview
A device is available to support the weight.
Technical data
The Powerblock is transported in a shipping box..
Power
PowerCompon.
Block

Mechanical
system

Motors

Options

General control

Closed-loop
control

Tools Comiss.
Communication
Diagnostics
Application rapid repair

Version: 19.11.2008 sin-g15-4-03-e.ppt I DT LD