Professional Documents
Culture Documents
Application Manual
2
General framework
3
Mechanical design
Sinamics S120 CM
Application Marine Drive 4
Type overview
Application Manual 5
Options
6
Technical data
7
Regulations and Standards
8
Contacts
9
Bibliography
12/2015
4BS0801-001
Introduction
Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well
as to prevent damage to property. The notices referring to your personal safety are highlighted in
the manual by a safety alert symbol, notices referring only to property damage have no safety alert
symbol. These notices shown below are graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
indicates that minor personal injury can result if proper precautions are not taken.
NOTICE
indicates that property damage can result if proper precautions are not taken.
If more than one degree of danger is present, the warning notice representing the highest degree
of danger will be used. A notice warning of injury to persons with a safety alert symbol may also in-
clude a warning relating to property damage.
Qualified Personnel
The product/system described in this documentation may be operated only by personnel qualified
for the specific task in accordance with the relevant documentation, in particular its warning notices
and safety instructions. Qualified personnel are those who, based on their training and experience,
are capable of identifying risks and avoiding potential hazards when working with these prod-
ucts/systems.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended
or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be complied with. The information in the relevant documentation must be observed.
Trademarks
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this publication may be trademarks whose use by third parties for their own purposes could violate
the rights of the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and
software described. Since variance cannot be precluded entirely, we cannot guarantee full con-
sistency. However, the information in this publication is reviewed regularly and any necessary cor-
rections are included in subsequent editions.
Table of contents
1 Introduction.............................................................................................................................................. 7
1.1 Field of application......................................................................................................................... 9
1.2 Topologies ................................................................................................................................... 10
2 General framework ................................................................................................................................ 13
2.1 Electrical ...................................................................................................................................... 13
2.2 Environment ................................................................................................................................ 14
2.3 Mechanical .................................................................................................................................. 15
2.4 Fluid cooling system .................................................................................................................... 15
3 Mechanical structures ............................................................................................................................ 17
3.1 Diode Line Module (DLM) ........................................................................................................... 18
3.2 Active Interface Module and Active Line Module (AIM+ALM) ..................................................... 20
3.3 Motor Module (MoMo) ................................................................................................................. 22
3.4 Brake chopper ............................................................................................................................. 23
3.5 Recooling Unit (RCU) .................................................................................................................. 25
3.6 Customer specific control cabinet ............................................................................................... 26
4 Type overview ....................................................................................................................................... 27
4.1 MLFB-Struktur ............................................................................................................................. 27
4.2 MLFB standard types .................................................................................................................. 29
5 Options .................................................................................................................................................. 31
6 Technical Data....................................................................................................................................... 39
6.1 Load profiles ................................................................................................................................ 39
6.2 Derating factors ........................................................................................................................... 40
6.2.1 Derating in case of increased ambient and cooling agent temperature ...................................... 40
6.2.2 Derating in case of power sections connected in parallel ........................................................... 42
6.2.3 Derating in case of low output frequency .................................................................................... 42
6.3 Interfaces ..................................................................................................................................... 43
6.4 Recooling Unit (RCU) .................................................................................................................. 44
6.5 Precharging/premagnetization .................................................................................................... 46
6.6 Brake chopper ............................................................................................................................. 49
7 Regulations and Standards .................................................................................................................... 50
8 Contacts ................................................................................................................................................ 51
9 Bibliography........................................................................................................................................... 52
1 Introduction
At first in this chapter one will find the typical fields of application. Thereupon, the
available topology ranging from a simple 6-pulse rectifier with defined energy flow
direction up to the complete 4-quadrant operation with active energy recovering unit
is presented.
Firstly in chapter Fehler! Verweisquelle konnte nicht gefunden werden. the elec-
trical, mechanical and environmental conditions are described, followed by the frame
conditions for the fluid cooling system.
In chapter “Mechanical structures the individual modular sections of the cabinet are
presented. In the following chapter “Type overview“ the structure of order numbering
is explained first, before the list of the standard types of S120 CM Application Marine
Drive.
Chapter 5 contains the options on the standard types presented before, including a
brief description of them. Technical details are shown in chapter 6.
Finally, chapter 7 shows the underlying standards and regulations, and in chapter
Fehler! Verweisquelle konnte nicht gefunden werden. that sales channel is
named which is the relevant contact for the product S120 CM Application Marine
Drive.
This application manual presents an overview on the setup and the functionality of
the Marine Drive. It shall serve as a basis for the first contact with the customer.
More detailed information can be found in the device-specific documentation.
The S120 CM Application Marine Drive is suitable for a multitude of applications. The stand-
ard types are starting with the power range of 560kW. Since, however, the installation of all
the sizes of power sections has been considered at the designing of the mechanical struc-
tures, smaller power sections as from 90kW on can be installed also.
The upper power limit is set at 5700kW, owing to the maximum four-circuit parallel connec-
tion of the biggest motor modules. The applicable power section units can be found in the
Device Manual [3].
Figure 1 is giving a survey on the essential fields of application of the S120 CM Application
Marine Drive. Generally, the drives were developed with view to ensuring safe and reliable
operation under the conditions aboard a ship. Here, especially the drive has to cope with the
dynamic line conditions and the varying load requirements.
Marine
Applications
Thruster Cranes
Compressors
1.2 Topologies
The input side of the frequency inverter consists of a Diode-Front-End-Module (DFE) in 6-,
12-, 18- or 24-pulse design that is connected to the mains either directly or via transformer.
Alternatively also an Active-Front-End (AFE) can be integrated, which will enable the recov-
ery of energy to the mains.
On the motor side a motor module (MoMo) is incorporated which can supply a three-phase
motor with closed-loop controlled frequency and voltage.
In case of higher power ranges, mains modules and motor modules as well can be operated
in parallel, on condition that the in-parallel connected modules are all of the same rated pow-
er and rated voltage. Moreover, in case of an in-parallel connection of power modules a cer-
tain derating has to be considered (see chapter 6.2).
Herebelow, a typical configuration for each infeed type is shown in a single-line diagram.
For special applications several motors can be run also in a DC-compound. It has to be con-
sidered, however, that upward from a certain number of axles, the Control Unit CU320-2 will
need the optional performance-extension (+K94) as a result of the computing time workload
(see also Chapter 5).
2 General framework
2.1 Electrical
Line frequency 50 Hz / 60 Hz
±5% permanently
±10% for 5 seconds
(To establish the tolerance limits the “worst case“-conditions of ship catagories DNV GL,
LR, ABS, BV, CCS and RINA MIL have been used)
2.2 Environment
Operating pressure of the max. 6 bar; rated infill pressure: 2.1 bar
cabinet system
2.3 Mechanical
Vibration strain during operation Requirement acc. to DNV Standard for Certification
No. 2.4 - Chapter 3.6:
”Sweep Sine Test“ as per chapter 3.6.2
Test strain as per Class A
Basis: Test acc. to IEC 60068-2-6
Other mechanical strain during Requirement acc. to DNV Standard for Certification
operation No. 2.4 - Chapter 3.11:
Static inclined position:
An inclination by 22,5° about the vertical axis must be
possible in all directions. Reference: the intended normal
fitting position.
out
Details regarding the applied recooling units may be found in chapter 6.4.
3 Mechanical structures
In order to meet the increased mechanical requirements on board of a ship, the selected con-
trol cabinets of series TS8 have been specified together with RITTAL.
Following additional measures have been taken:
In the following, the individual power sections and sub-assemblies in the respective standard
modular cabinet section are presented. The CAD-transfers do not always represent all op-
tions and design variants. If there are any adaptations necessary in the details, these can be
worked out in course of the offer engineering.
Cabinet fittings:
1. DC-link busbar
2. 2 Diode Line Modules (DLM) 1700kW
without line reactor configuration for
2 the operation on a 3-winding trans-
3 former (12-pulse)
3. Option Y51 transformer for pre-
3 charging and premagnetization
3 4. Area for customer- connections with
three busbars per DLM
5. Earth bus with rear-mounted cable-
6 entry clamping profiles and control
3 cable connector on the left, vertically
on the side wall
6. Hinged frame (shown here in opened
position) for the reception of control
4
components.
3
5
3
Cabinet fittings:
2 Picture as before, but the hinged rack
for the reception of control compo-
3
nents is shown in closed position.
Cabinet fittings:
1. Filter network
2. Line reactor
3. Terminals for mains connection
6 4. Earth bus
Cabinet fittings:
5. DC-link busbar with fusing
6. Active Line Modul (ALM)
4
3
ALM Variant 2:
Back-to-back mounting
AIM
AIM cabinet: height 2200mm, width
5 800mm, depth 800mm (front)
1 Cabinet fittings:
1. Filter network
2. Line reactor
3. Terminals for mains connection
6 4. Earth bus
3 4
Cabinet fittings:
1 1. DC-link busbar with fusing
2. Motor Modul (shown: max. size JXL
with 1500kW)
3. Area for customer-connections with
three busbars toward the depth for
2 the power connection of the motor
4. Earth bus with rear-mounted cable-
entry clamping profiles toward the
depth
Cabinet fittings:
1 1. DC-link busbar with fusing
2. Brake chopper module
3. Connecting area for the customer
with two busbars for a 2-phase brake
resistor
2 4. Earth bus with rear-mounted cable-
entry clamping profiles
Cabinet fittings:
2 1. Mounting plate for individual treatment for
control components
4 Type overview
Die folgenden Unterkapitel beschreiben die MLFB-Struktur des S120CM Application Marine
Drive in general and the standard types in particular.
4.1 MLFB-Struktur
LV Marine Drives
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
n a a n n n n n a a n n n a a n
8. item : Harmonics 6 S E 0 . . . - . . . . . - . . . .
6-puls 1
12-puls 2
18-puls 3
24-puls 4
Active Frontend 8
9. item : Quantity of parallel MOMO-units*) 6 S E 0 . . . - . . . . . - . . . .
Cabinet incl. 1 MOMO (Motormodule) A
Cabinet incl. 2 MOMO (Motormodule) B
Cabinet incl. 3 MOMO (Motormodule) C
Cabinet incl. ... MOMO (Motormodule) …
*) quantity of momos w ithout braking module
Figure 12: MLFB structure S120CM Application Marine Drive - part 1
LV Marine Drives
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
n a a n n n n n a a n n n a a n
For the types listed, standard dimension drawings and data sheets are available (see [1]).
5 Options
Basic configuration of the standard devices:
- Class of protection IP43 with integrated cabinet ventilation
- Anti-condensation heating
- CU320-2 DP (Profibus)
- Terminal Module TM41 (4xDI/DO; 4xDI; 1xAI; 1xTTL)
- Advanced operator panel (AOP30), mounted in the cabinet door
- Handle on each door with operating elements
- Welded base frame
- Fuse monitoring
- Leackage monitoring
- Door arresting device
- Recooling system with single pump and water-connection from below
- Cable-end marking
The following options can be ordered individually for each unit by adding ”–Z“ to the MLFB
and subsequently with ”+“ for each further option code:
K21 Indicators
(voltage output, current output, power output and speed (4x analog))
At the service door the following indicator elements will be integrated additionally:
- Analog indicator “voltage output” 72x72mm
- Analog indicator “current output” 72x72mm
- Analog indicator “power output” 72x72mm
- Analog indicator “speed“ 72x72mm
There has to be checked for each individual case whether or not the performance extension
for special applications is required. For dimensioning and selection see [5] chapter 6.2.
This performance extension that is subject to license is basically required:
- from the 4th Motor Module with servo-control, i.e. from the 4 th Servo-axis,
- from the 4 th Motor Module with vector- control, i.e. from the 4 th Vektor-axis,
- from the 7 th Motor Module with U/f-control, i.e. from the 7 th U/f-axis.
If supply voltages deviating from the above ones are demanded, the required voltages can be
adapted upon request, by means of internal transformers or converters.
6 Technical Data
All motor-side power inverters S120 (motor modules) are laid-out for two defined standard
load cycle types. To each load cycle a defined maximum base-load current is underlying.
The output currents of the standard types in chapter 4.2 are the rated currents. If there is no
load cycle in progress this current can be applied for the layout. Following figures however
are showing that in case of application of load cycles, lower base-load currents must be con-
sidered for the layout.
The base-load currents and also the load cycles are available in [3] under the technical data
of the motor modules.
If the application requires totally different load cycles, even project-specific load cycles can
be calculated, see [4] Chapter 1.13.
Following, the two standard load cycles for low and high overload are presented.
Each inverter system is laid-out for certain frame conditions. When these frame conditions
are exceeded or undershot, either derating factors have to be applied or bringing into use is
not possible. Owing to the high number of application fields numerous derating factors for
different influencing factors are existing.
Following, the most important derating factors for the Application Marine Drive are itemized
only in keywords. For more detailed information we refer to the respective chapters in the
Projecting Manual [4] or the Instruction Manual of the Device [3].
Figure 19: Derating of the output current in case of increased ambient temperature
Figure 20: Derating of the output current in case of increased cooling agent temperature
In the Marine area, particularly with slow running shaft generators or with winches, cranes or
other hoisting equipment derating may become necessary owing to the low output frequen-
cies.
Here it is always distinguished whether the low output frequencies can occur with rated load
or if additional overload is required. Besides, there is a distinction whether the operation with
low output frequencies exceeds 2% of the operating life or less.
In the following diagram, only the Worst-Case derating-characteristic is considered. For more
detailed considerations see the Project Manual [4], Chapter 1.12.3.
Figure 21: admissible short-time current and permissible base-load current in case of a frequently occurring high overload, depend-
ent from the output frequency
6.3 Interfaces
Subsequently, the possible interfaces of the SINAMICS S120 CM Application Marine Drive to
external areas are shown. The components shown with dotted lines are options. These are
described in greater detail in chapter 5.
Figure 22: Possible interfaces between SINAMICS S120 CM Application Marine Drive and external areas
The power sections are provided with an aluminium cooling plate and are cooled by means of
an Antifrogen N mixture. This is a closed cooling circuit. Its temperature is controlled by the
recooling unit, and it is cooled by the fresh-water cooling circuit of the ship.
The RCU is an independent unit in a cabinet of its own and is provided with a separate con-
trol unit. The pump (Figure 23, Item 60.1) for the closed inverter circuit which is integrated
into the RCU can optionally be run redundantly (Item 60.2). The thermal energy will be trans-
fered by a water-water heat exchange system (Item 50). With an open-loop controlled 3-way
valve (Item 61) part of the inverter coolant will be fed-back uncooled into the inverter flow, in
order to keep the flow temperature on a consistent level. In this way, condensation is pre-
vented and also the aging of the IGBTs owing to a fluctuating temperature is avoided.
Those components in the inverter cabinets that have to be cooled are connected in parallel
as shown in Figure 24. So that this hard parallel connection will be functioning, all compo-
nents are showing a pressure drop of 0.7bar.
Characteristic 32 kW 48 kW 72 kW 110 kW
Power range 22 – 32 32 – 48 48 – 72 72 – 110
[kW]
Volume flow rate of the 3.6 – 5.3 5,3 – 7.9 7.9 – 11.8 11.8 – 16
cooling agent
[m³/h]
Dimensions 690x1500x550 890x1500x550 1090x1700x550 1090x1700x550
[BxHxT, mm]
Dimensions of cabinet 800x2200x800 1000x2200x800 1200x2200x800 1200x2200x800
[BxHxT, mm]
Electrical power . appr. 2,3 appr. 4.1 appr. 4.1
consumption
[kW]
6.5 Precharging/premagnetization
During the process of precharging the DC-link and premagnetizing the power transformer the
motor modules are not in operation. Beside of the precharge/premagnetizing transformer no
further power components (like external reactors or resistors) are required for the precharg-
ing and premagnetizing process.
Once the power transformer has taken over the supply of the DC- link, the precharge /pre-
magnetizing transformer is switched out of the circuit via contactor.
Auxiliary network
Hilfsnetz
Vorlade-/ /
Precharging
Vormagnetisierungs-
premagnetizing
Trafo
transformer
Dioden-
Diode
B6-Brücke
B6 bridge
Zwischenkreis
DC-link with
mit capacitors
dc-link ZK-Konden-
satoren
and und
Symmetrier-
balancing resistors
widerständen
IGBT-
IGBT
B6-Brücke
B6 bridge
This Single-line diagram applies to all drives with Diode Front End, where the power trans-
former is uncoupled during the precharging process (no premagnetizing). It is a 6-pulse pre-
charging as the precharge transformer is always connected to only one of possibly several
feed-in legs. Here, the outlined diode B6 bridge can be a complete 6-pulse diode line module,
a part of the 12-pulse 1700kW diode line module or a separate diode bridge (e.g. in case of a
shaft generator application).
Independently from the above the DC-link, presented in the picture as one unit, comprises
the capacitors and balancing resistors of all modules (diode line modules, active line mod-
ules, motor modules) that are connected to the DC-link. The presented IGBT B6 bridge
symbolises one motor module. This is not in operation during the precharging process.
Power Leistungstrafo
transformer
Schalter
Switch
Hilfsnetz network
Auxiliary
Vorlade-/ /
Precharging
Vormagnetisierungs-
premagnetizing
Trafo
transformer
Dioden-
Diode
B6-Brücke
B6 bridge
Zwischenkreis
DC-link with
mit ZK-Konden-
dc-link capacitors
satoren und
and
Symmetrier-
balancing resistors
widerständen
IGBT-
IGBT-
B6 bridge
B6-Brücke
This Single-Line-Diagramm applies to drives with Diode Front End and 6-pulse infeed into the
DC-link, where the power transformer is coupled during the precharging process. Thus, a
premagnetization of the power transformer is performed at the same time.
Hauptnetz
Main network
Leistungstrafo
Power transformer
Switch
Schalter
Hilfsnetz
Auxiliary network
Vorlade-//
Precharging
Vormagnetisierungs-
premagnetizing
Trafo
transformer
Diode Diode
Dioden-
B6 bridge Dioden-
B6 bridge
B6-Brücke B6-Brücke
DC-link with
Zwischenkreis
dc-link capaci-
mit ZK-Konden-
tors andund
satoren
balancing
Symmetrier-
resistors
widerständen
IGBT
B6IGBT-
bridge
B6-Brücke
This Single-Line-Diagramm applies to all drives with Diode Front End and 12-pulse infeed
into the DC-link, where the power transformer is coupled during the precharging process.
Thus, a premagnetization of the power transformer is performed at the same time. The here
shown Diode B6 bridges may represent here a 12-pulse 1700kW-DLM or a parallel connec-
tion of two 6-pulse DLMs. The shown IGBT B6 bridge symbolizes a motor module (in place of
possibly several motor modules).
Since the power transformer is interfaced, and its secondary winding is coupled by the mag-
netic field, also the second infeed leg is used on precharging. Thus, there will be a 12-pulse
precharging.
In case of a 18- and 24-pulse precharging and premagnetization, this Single-Line-Diagram
has to be extended by a third and/or fourth infeed leg.
For the function as brake modules either motor modules or special brake chopper modules
can be used.
In case a motor module is used three adequately dimensioned external brake resistors have
to be connected in star configuration. For detailed information see the projecting manual [4],
chapter 6.8.3.
If a special brake module is used an external brake resistor will be connected which has to be
laid-out for the respective application. Two versions of brake modules of a subsupplier are
available:
- Type TRANSOMIK 630BC2/690
- Type TRANSOMIK 1200BC2/690
The relevant technical data of the modules are listed here:
Designation TRANSOMIK
Repeated braking:
- Current
- Duty cycle with ventilator
- Cycle time
- Rmin with
Permanent braking: or or
- Current
- Duty cycle with ventilator
- Cycle time
- Rmin with
Installation, Erection:
Weight
Dimensions: - Height with ventilator
- Width
- Depth
Cooling - Ventilator
max. power loss
Type of connection Cable lug M8 or rail
Clamping ability
Tigfhtening torque
min. DC-link capacity of frequency inverter
Figure 28: Technical data TRANSOMIK brake modules 630BC2/690 and 1200BC2/690
The following list presents the relevant product specific standards and indicates the
classification bodies who’s relevant regulations are considered as the standard.
IEC-Standards
- DIN EN 61800-5-1, issued in April 2008
- DIN EN 61800-3, issued in September 2012
- DIN EN 60204-1, issued in Juni 2007
Ship’s classification
- DNV
- GL
- LR
- ABS
- BV
- CCS
- RINA
- IACS
8 Contacts
9 Bibliography
[1] Siemens AG, “Control Units und ergänzende Systemkomponenten,“ 04/ 2015. [Online]. Available:
https://support.industry.siemens.com/cs/ww/de/view/109478725. [Access 27. 08. 2015].
[2] Siemens AG, „Flyer - S120 CM Application Marine Drive,“ 2015. [Online]. Available:
http://w3app.siemens.com/mcms/infocenter/content/de/Seiten/
order_form.aspx?nodeKey=key_9174328&infotype=brochures&linkit=9f68b46b-1d10-45a7-9153-
20ac29c5ab1e. [Access 27. 08. 2015].
[3] Siemens AG, “S120 Leistungsteile Chassis flüssigkeitsgekühlt - Gerätehandbuch,“ 12/ 2014. [Online].
Available: https://support.industry.siemens.com/cs/ww/de/view/109210431. [Access 27. 08. 2015].
[4] Siemens AG, „SINAMICS - Low Voltage Projektierungshandbuch,“ 09/ 2014. [Online]. Available:
http://w3app.siemens.com/mcms/infocenter/dokumentencenter/ld/InfocenterLanguagePacks/sinamics-
projektierungshandbuch-lv/sinamics-projektierungshandbuch-lv-de.pdf. [Access 27. 08. 2015].