Siemens SINAMICS S120 Technical Document

SINAMICS
Equipment Manual· 05/2010
SINAMICS S120 Combi
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SINAMICS
S120
SINAMICS S120 Combi
Manual
Edition 05.2010
6SL3097-4AV00-0BP0
Preface
System overview
1
Line-side power components
2
S120 Combi Power Modules
3
External fan unit
4
Topology rules for DRIVE-
CLiQ
5
Motor Modules Booksize
Compact as expansion axes
6
DC link components
7
Electrically connecting Motor
Modules and DC link
components
8
Additional system
components
9
Encoder system connection
10
Accessories
11
Cabinet design and EMC
12
Service and maintenance
13
Appendix
A

Legal information
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
with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.
CAUTION
without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.
NOTICE
indicates that an unintended result or situation can occur if the corresponding information is not taken into
account.
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 include 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 for the specific task, 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 products/systems.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, 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 adhered to. The information in the relevant documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of the Siemens AG. The remaining trademarks in 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 consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.
Siemens AG
Industry Sector
Postfach 48 48
90026 NÜRNBERG
GERMANY
order number: 6SL3097-4AV00-0BP0
Ⓟ 06/2010
Copyright © Siemens AG 2010.
Technical data subject to change

SINAMICS S120 Combi
Manual, Edition 05.2010, 6SL3097-4AV00-0BP0 5
Preface
Preface
SINAMICS documentation
The SINAMICS documentation is organized in 2 parts:
● General documentation / Catalogs
● Manufacturer / Service documentation
You can find more information on the following topics at
http://www.siemens.com/motioncontrol/docu:
● Ordering documentation
Here you can find an up-to-date overview of publications
● Downloading documentation
Further links for downloading files from Service & Support
● Researching documentation online
Information on DOConCD and direct access to the publications in DOConWeb.
● For customizing documentation based on Siemens content using My Documentation
Manager (MDM), see
http://www.siemens.com/mdm
My Documentation Manager provides you with a range of features for creating your own
machine documentation
● Training and FAQs
Information about training courses and FAQs (Frequently Asked Questions) can be found
using the page navigation.

Preface
SINAMICS S120 Combi
6 Manual, Edition 05.2010, 6SL3097-4AV00-0BP0
Usage phases
Table 1 Usage phase and the available documents/tools
Usage phase Tools
Orientation SINAMICS S Sales Documentation
Planning/configuration SIZER configuration tool
Decision making/ordering SINAMICS S Catalogs
Configuring/installation •SINAMICS S120 Manuals
•SINAMICS S120 Combi Manual
•SINUMERIK 828D PPU Manual
Commissioning •SINAMICS S120 Combi List Manual
•SINUMERIK 828D Turning and Milling Commissioning Manual
Usage/operation •SINAMICS S120 Function Manual FH1
•SINAMICS S120 Combi List Manual
Maintenance/Service •SINAMICS S120 Combi Manual
•SINAMICS S120 Combi List Manual
Target group
This Manual addresses planners, installation technicians, design engineers.
Benefits
This manual provides information on the components and functions of devices so that the
target group is capable of installing, setting up, testing, operating, and troubleshooting the
devices safely and correctly.
Standard scope
This documentation only describes the functionality of the standard version. Extensions or
changes made by the machine tool manufacturer are documented by the machine tool
manufacturer.
Other functions not described in this documentation might be able to be executed in the drive
system. This does not, however, represent an obligation to supply such functions with a new
control or when servicing.
Further, for the sake of simplicity, this documentation does not contain all detailed
information about all types of the product and cannot cover every conceivable case of
installation, operation or maintenance.

Preface
SINAMICS S120 Combi
Manual, Edition 05.2010, 6SL3097-4AV00-0BP0 7
Technical support
If you have any questions, please contact our hotline:
Europe/Africa
Telephone [phone] - 222
Fax [phone] - 223
€ 0.14/min. from German landlines, max. € 0.42/min. for mobile calls within Germany
Internet http://www.siemens.de/automation/support-request
Americas
Telephone [phone]
Fax [phone]
E-mail mailto:[email protected]
Asia/Pacific
Telephone [phone]
Fax [phone]
E-mail mailto:support.asia.automatio[email protected]
Note
You will find telephone numbers for other countries for technical support on the Internet:
http://www.automation.siemens.com/partner
Spare parts
Spare parts are available on the Internet at:
http://support.automation.siemens.com/WW/view/de/16612315
Questions about the documentation
If you have any questions (suggestions, corrections) regarding this documentation, please
fax or e-mail us at:
Fax [phone]
E-mail E-mail to: [email protected]
A fax form is available in the appendix of this document.
Internet address for SINAMICS
http://www.siemens.com/sinamics.

Preface
SINAMICS S120 Combi
8 Manual, Edition 05.2010, 6SL3097-4AV00-0BP0
Test certificates
The Safety Integrated functions of SINAMICS components are generally certified by
independent institutes. An up-to-date list of certified components is available on request from
your local Siemens office. If you have any questions relating to certifications that have not
been completed, please ask your Siemens contact.
EC Declarations of Conformity
The EC Declaration of Conformity for the EMC Directive can be found/obtained:
● on the Internet:
http://support.automation.siemens.com
under the Product/Order number 15257461
● at the relevant regional office of the I DT MC Business Unit of Siemens AG
The EC Declaration of Conformity for the Low Voltage Directive can be found/obtained
● on the Internet
http://support.automation.siemens.com
under the Product/Order number 22383669
Note
When operated in dry areas, SINAMICS S devices conform to the Low Voltage Directive
73/23/EEC or 2006/95/EEC.
Note
SINAMICS S devices fulfill EMC Directive 89/336/EEC or 2004/108/EC in the configuration
specified in the associated EC Declaration of Conformity and when the EMC installation
guideline is implemented, Order No. 6FC5297-0AD30-0P.
Note
The Equipment Manual describes a desired state which, if maintained, ensures reliable
operation as desired and compliance with EMC limit values.
Should there be a deviation from the Equipment Manual requirements, appropriate actions
(e.g. measurements) must be taken to check/prove that the desired reliable operation is
ensured and EMC limit values are complied with.

Preface
SINAMICS S120 Combi
Manual, Edition 05.2010, 6SL3097-4AV00-0BP0 9
DANGER
Electrical, magnetic and electromagnetic fields (EMF) that occur during operation can pose
a danger to persons who are present in the direct vicinity of the product - especially
persons with pacemakers, implants, or similar devices.
The relevant directives and standards must be observed by the machine/plant operators
and persons present in the vicinity of the product. These are, for example, EMF Directive
2004/40/EEC and standards EN 12198-1 to -3 applying to the European Economic Area
(EEA) and in Germany the accident prevention regulation BGV 11 and the associated rule
BGR 11 "Electromagnetic fields" from the German employer's liability accident insurance
association.
These state that a hazard analysis must drawn up for every workplace, from which
measures for reducing dangers and their impact on persons are derived and applied, and
exposure and danger zones are defined and observed.
The relevant safety notes in each chapter must be observed.
ESD information
CAUTION
Electrostatic sensitive devices (ESDs) are individual components, integrated circuits, or
boards that may be damaged by either electrostatic fields or electrostatic discharge.
Regulations for handling ESD components:
When handling electronic components, you must ensure that the person carrying out the
work, the work place, and packaging are properly grounded.
Personnel may only come into contact with electronic components, if
•They are grounded with an ESD wrist band, or
•They are in ESD areas with conductive flooring, ESD shoes or ESD grounding straps.
Electronic boards should only be touched if absolutely necessary. They must only be
handled on the front panel or, in the case of printed circuit boards, at the edge.
Electronic boards must not come into contact with plastics or items of clothing containing
synthetic fibers.
Boards must only be placed on conductive surfaces (work surfaces with ESD surface,
conductive ESD foam, ESD packing bag, ESD transport container).
Do not place boards near display units, monitors, or television sets (minimum distance from
screen: 10 cm).
Measurements may only be taken on boards when the measuring device is grounded (via
protective conductors, for example) or the measuring probe is briefly discharged before
measurements are taken with an isolated measuring device (for example, touching a bare
metal enclosure).

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SINAMICS S120 Combi
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Safety information
DANGER
Commissioning is absolutely prohibited until it has been completely ensured that the
machine, in which the components described here are to be installed, is in full compliance
with the provisions of the EC Machinery Directive.
Only qualified personnel may install, commission and service SINAMICS S units.
The personnel must take into account the information provided in the technical customer
documentation for the product, and be familiar with and observe the specified danger and
warning notices.
Operational electrical equipment and motors have parts and components which are at
hazardous voltage levels that may cause serious injuries or death when touched.
All work on the electrical system must be carried out when the system has been
disconnected from the power supply.
In combination with the drive system, the motors are generally approved for operation on
TN and TT line supplies with grounded neutral and on IT line supplies.
In operation on IT line supplies, 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 should be eliminated as quickly as practically possible.
For line supplies with a grounded phase conductor, an isolating transformer with grounded
neutral (secondary side) must be connected between the supply and the drive system to
protect the motor insulation from excessive stress. The majority of TT line supplies have a
grounded phase conductor, so in this case an isolating transformer must be used.
DANGER
Correct and safe operation of SINAMICS S units assumes correct transportation in the
transport packaging, correct long-term storage in the transport packaging, setup and
installation, as well as careful operation and maintenance.
The details in the catalogs and proposals also apply to the design of special equipment
versions.
In addition to the danger and warning information provided in the technical customer
documentation, the applicable national, local, and system-specific regulations and
requirements must be taken into account.
According to EN 61800-5-1 and UL 508 only safely isolated protective extra-low voltages of
the electronic modules may be connected to all connections and terminals.

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SINAMICS S120 Combi
Manual, Edition 05.2010, 6SL3097-4AV00-0BP0 11
DANGER
Using protection against direct contact via DVC A (PELV) is only permissible in areas with
equipotential bonding and in dry rooms indoors. If these conditions are not fulfilled, other
protective measures against electric shock (e.g. protection through protective impedances
or limited voltage, or use of protection class I and II) must be used.
DANGER
As part of routine tests, SINAMICS S components will undergo a voltage test in accordance
with EN 61800-5-1. Before the voltage test is performed on the electrical equipment of
machines to EN 60204-1, Section 18.4, all connections of SINAMICS units must be
disconnected/unplugged to prevent them from being damaged.
Motors should be connected up corresponding to the circuit diagram supplied with the
motor (refer to the connection examples of Motor Modules). They must not be connected
directly to the three-phase supply because this will damage them.
WARNING
Operating the equipment in the immediate vicinity (< 1.8 m) of mobile telephones with a
transmitter power of > 1 W may cause the equipment to malfunction.
Explanation of symbols
Table 2 Symbols
Symbol Meaning
Protective earth (PE)
Ground (e.g. M 24 V)
Functional ground
Equipotential bonding

Preface
SINAMICS S120 Combi
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Residual risks
Residual risks of power drive systems
The control and drive components of a power drive system (PDS) are approved for industrial
and commercial use in industrial line supplies. Their use in public line supplies requires a
different configuration and/or additional measures.
These components may only be operated in closed housings or in higher-level control
cabinets and when all of the protective devices and protective covers are used.
These components may only be handled by qualified and trained technical personnel who
are knowledgeable and observe all of the safety information and instructions on the
components and in the associated technical user documentation.
When carrying out a risk assessment of a machine in accordance with the EU Machinery
Directive, the machine manufacturer must consider the following residual risks associated
with the control and drive components of a power drive system (PDS).
1. Unintentional movements of driven machine components during commissioning,
operation, maintenance, and repairs caused by, for example:
– Hardware defects and/or software errors in the sensors, controllers, actuators, and
connection technology
– Response times of the controller and drive
– Operating and/or ambient conditions not within the scope of the specification
– Condensation / conductive contamination
– Parameterization, programming, cabling, and installation errors
– Use of radio devices / cellular phones in the immediate vicinity of the controller
– External influences / damage
2. Exceptional temperatures as well as emissions of light, noise, particles, or gas caused by,
for example:
– Component malfunctions
– Software errors
– Operating and/or ambient conditions not within the scope of the specification
– External influences / damage
3. Hazardous shock voltages caused by, for example:
– Component malfunctions
– Influence of electrostatic charging
– Induction of voltages in moving motors
– Operating and/or ambient conditions not within the scope of the specification
– Condensation / conductive contamination
– External influences / damage

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SINAMICS S120 Combi
Manual, Edition 05.2010, 6SL3097-4AV00-0BP0 13
4. Electrical, magnetic and electromagnetic fields generated in operation that can pose a
risk to people with a pacemaker, implants or metal replacement joints, etc. if they are too
close.
5. Release of environmental pollutants or emissions as a result of improper operation of the
system and/or failure to dispose of components safely and correctly.
For more information about residual risks of the power drive system components, see the
relevant chapters in the technical user documentation.

Preface
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SINAMICS S120 Combi
Manual, Edition 05.2010, 6SL3097-4AV00-0BP0 15
Table of contents
Preface ...................................................................................................................................................... 5
1 System overview...................................................................................................................................... 21
1.1 SINAMICS S120 Combi components ..........................................................................................21
1.2 System data .................................................................................................................................23
1.3 Standards.....................................................................................................................................25
2 Line-side power components................................................................................................................... 29
2.1 Introduction ..................................................................................................................................29
2.2 Information on the disconnector unit............................................................................................30
2.3 Overcurrent protection by means of line fuses and circuit breakers............................................30
2.4 Line supply connection via residual-current devices ...................................................................33
2.5 Overvoltage protection.................................................................................................................34
2.6 Line filters.....................................................................................................................................35
2.6.1 Description ...................................................................................................................................35
2.6.2 Safety information ........................................................................................................................35
2.6.3 Interface description.....................................................................................................................37
2.6.3.1 Overview ......................................................................................................................................37
2.6.3.2 Line/load connection ....................................................................................................................38
2.6.4 Dimension drawing ......................................................................................................................39
2.6.5 Technical data..............................................................................................................................39
2.7 Line reactors ................................................................................................................................40
2.7.1 Description ...................................................................................................................................40
2.7.2 Safety information ........................................................................................................................40
2.7.3 Connection description ................................................................................................................41
2.7.3.1 Overview ......................................................................................................................................41
2.7.3.2 Line/load connection ....................................................................................................................41
2.7.4 Dimension drawings.....................................................................................................................42
2.7.5 Technical data..............................................................................................................................43
2.8 Line connection versions .............................................................................................................44
2.8.1 Ways of connecting the line supply .............................................................................................44
2.8.2 Operating line connection components on the line supply ..........................................................45
2.8.3 Operation of the line connection components via a transformer .................................................46
2.8.3.1 Safety information ........................................................................................................................46
2.8.3.2 Line connection conditions...........................................................................................................46
2.8.3.3 Operation via a matching transformer .........................................................................................52
2.8.3.4 Operation via an isolation transformer.........................................................................................54
2.8.3.5 Dimension drawings of the transformers .....................................................................................57
2.8.3.6 Technical specifications of the transformers................................................................................60

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16 Manual, Edition 05.2010, 6SL3097-4AV00-0BP0
3 S120 Combi Power Modules ................................................................................................................... 63
3.1 Introduction ................................................................................................................................. 63
3.1.1 Description .................................................................................................................................. 63
3.1.2 Module versions .......................................................................................................................... 65
3.1.3 Approved controls ....................................................................................................................... 65
3.1.4 Expansion axes that can be connected ...................................................................................... 66
3.2 Safety information ....................................................................................................................... 66
3.3 Interface description.................................................................................................................... 70
3.3.1 Overview diagrams ..................................................................................................................... 70
3.3.2 Connection example ................................................................................................................... 76
3.3.3 X1 line connection....................................................................................................................... 77
3.3.4 X2-X5 motor connection.............................................................................................................. 77
3.3.5 X11 brake connection ................................................................................................................. 79
3.3.6 X12/X13 fan connection.............................................................................................................. 80
3.3.7 X21/X22 EP terminals................................................................................................................. 81
3.3.8 X200-X205 DRIVE-CLiQ interfaces ............................................................................................ 82
3.3.9 X220 TTL encoder ...................................................................................................................... 83
3.3.10 X224 24 V DC plug ..................................................................................................................... 87
3.3.11 Meaning of the LEDs on the S120 Combi...................................................................................88
3.4 Dimension drawings.................................................................................................................... 89
3.5 Installation ................................................................................................................................... 90
3.5.1 Drilling patterns and installation cut-outs .................................................................................... 90
3.5.2 Installing the reinforcement plates for an S120 Combi Power Module....................................... 92
3.5.3 Installing an S120 Combi Power Module....................................................................................95
3.6 Electrical connection ................................................................................................................... 96
3.6.1 Line supply cable ........................................................................................................................ 97
3.6.2 Power cables for motors ............................................................................................................. 98
3.6.3 Signal cables at the EP terminals ............................................................................................... 99
3.7 Technical data........................................................................................................................... 100
3.7.1 Characteristics .......................................................................................................................... 105
4 External fan unit..................................................................................................................................... 109
4.1 Description ................................................................................................................................ 109
4.2 Overview ................................................................................................................................... 110
4.3 Dimension drawing.................................................................................................................... 111
4.4 Installation ................................................................................................................................. 112
4.5 Technical data........................................................................................................................... 115
5 Topology rules for DRIVE-CLiQ............................................................................................................. 117
5.1 Connection examples................................................................................................................ 119
6 Motor Modules Booksize Compact as expansion axes.......................................................................... 123
6.1 Description ................................................................................................................................ 123
6.2 Safety information ..................................................................................................................... 123
6.3 Interface description.................................................................................................................. 126
6.3.1 Overview ................................................................................................................................... 126
6.3.2 Connection example ................................................................................................................. 128
6.3.3 X1 Motor connection ................................................................................................................. 129

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6.3.4 X12 motor brake connection......................................................................................................130
6.3.5 X21/X22 EP terminals / temperature sensor Motor Module ......................................................131
6.3.6 X200-X203 DRIVE-CLiQ interface.............................................................................................132
6.3.7 Meaning of the LEDs on the Motor Module Booksize Compact................................................133
6.4 Dimension drawings...................................................................................................................134
6.5 Installation..................................................................................................................................137
6.6 Technical data............................................................................................................................138
6.6.1 Characteristics ...........................................................................................................................140
7 DC link components............................................................................................................................... 145
7.1 Braking Module ..........................................................................................................................145
7.1.1 Description .................................................................................................................................145
7.1.2 Safety information ......................................................................................................................146
7.1.3 Interface description...................................................................................................................147
7.1.3.1 Overview ....................................................................................................................................147
7.1.3.2 Connection example ..................................................................................................................148
7.1.3.3 X1 braking resistor connection...................................................................................................148
7.1.3.4 X21 digital inputs/outputs...........................................................................................................149
7.1.3.5 Meaning of the LEDs on the Braking Module ............................................................................150
7.1.4 Dimension drawing ....................................................................................................................151
7.1.5 Installation..................................................................................................................................152
7.1.6 Technical data............................................................................................................................153
7.1.7 Braking resistors for Braking Modules.......................................................................................153
7.1.7.1 Installation of the braking resistors ............................................................................................153
7.1.7.2 Dimension drawings...................................................................................................................154
7.1.7.3 Technical data............................................................................................................................156
7.2 Control Supply Module CSM......................................................................................................157
7.2.1 Description .................................................................................................................................157
7.2.2 Safety information ......................................................................................................................158
7.2.3 Interface description...................................................................................................................159
7.2.3.1 Overview ....................................................................................................................................159
7.2.3.2 Connection examples ................................................................................................................160
7.2.3.3 X1 line connection......................................................................................................................162
7.2.3.4 X24 24 V terminal adapter .........................................................................................................162
7.2.3.5 X21 signaling contact.................................................................................................................163
7.2.3.6 S1 DIP switch.............................................................................................................................164
7.2.3.7 Meaning of the LEDs on the Control Supply Module.................................................................165
7.2.4 Dimension drawing ....................................................................................................................166
7.2.5 Installation..................................................................................................................................167
7.2.6 Technical data............................................................................................................................168
8 Electrically connecting Motor Modules and DC link components ........................................................... 169
8.1 Introduction ................................................................................................................................169
8.2 Removing the front cover and opening the DC link cover on the S120 Combi .........................169
8.3 Connecting the DC link busbars and 24 V busbars...................................................................171
8.4 Connecting an additional component ........................................................................................173
9 Additional system components .............................................................................................................. 175
9.1 Terminal Module TM54F............................................................................................................175
9.1.1 Description .................................................................................................................................175
9.1.2 Safety information ......................................................................................................................176

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9.1.3 Interface description.................................................................................................................. 177
9.1.3.1 Overview ................................................................................................................................... 177
9.1.3.2 Connection example ................................................................................................................. 178
9.1.3.3 X500 and X501 DRIVE-CLiQ interface.....................................................................................179
9.1.3.4 X514 power supply for digital outputs and sensors .................................................................. 179
9.1.3.5 X520 sensor power supply........................................................................................................ 180
9.1.3.6 X521 Digital inputs and dynamically adjustable power supply ................................................. 180
9.1.3.7 X522 digital inputs..................................................................................................................... 181
9.1.3.8 X523 digital outputs................................................................................................................... 182
9.1.3.9 X524 Electronics power supply................................................................................................. 183
9.1.3.10 X525 digital outputs................................................................................................................... 184
9.1.3.11 X531 digital inputs and dynamically adjustable power supply .................................................. 185
9.1.3.12 X532 digital inputs..................................................................................................................... 186
9.1.3.13 X533 digital outputs................................................................................................................... 187
9.1.3.14 X535 digital outputs................................................................................................................... 188
9.1.3.15 Meaning of the LEDs on the Terminal Module TM54F............................................................. 189
9.1.4 Dimension drawing.................................................................................................................... 191
9.1.5 Installation ................................................................................................................................. 192
9.1.6 Protective conductor connection and shield support ................................................................ 193
9.1.7 Technical data........................................................................................................................... 194
9.2 DRIVE-CLiQ Hub Module DMC20............................................................................................ 195
9.2.1 Description ................................................................................................................................ 195
9.2.2 Safety information ..................................................................................................................... 195
9.2.3 Interface description.................................................................................................................. 196
9.2.3.1 Overview ................................................................................................................................... 196
9.2.3.2 X524 Electronics power supply................................................................................................. 197
9.2.3.3 X500 - X505 DRIVE-CLiQ interfaces........................................................................................ 197
9.2.3.4 Meaning of the LED on the DMC20.......................................................................................... 198
9.2.4 Dimension drawing.................................................................................................................... 199
9.2.5 Installation ................................................................................................................................. 200
9.2.6 Technical data........................................................................................................................... 201
9.3 DRIVE-CLiQ Hub Module External DME20.............................................................................. 202
9.3.1 Description ................................................................................................................................ 202
9.3.2 Safety information ..................................................................................................................... 202
9.3.3 Interface description.................................................................................................................. 203
9.3.3.1 Overview ................................................................................................................................... 203
9.3.3.2 X524 Electronics power supply................................................................................................. 204
9.3.3.3 X500 - X505 DRIVE-CLiQ interfaces........................................................................................ 205
9.3.4 Dimension drawing.................................................................................................................... 206
9.3.5 Installation ................................................................................................................................. 207
9.3.6 Technical data........................................................................................................................... 208
9.3.7 Specifications for use with UL approval .................................................................................... 209
10 Encoder system connection................................................................................................................... 211
10.1 Sensor Module Cabinet-Mounted SMC20 ................................................................................ 211
10.1.1 Description ................................................................................................................................ 211
10.1.2 Safety information ..................................................................................................................... 211
10.1.3 Interface description.................................................................................................................. 212
10.1.3.1 Overview ................................................................................................................................... 212
10.1.3.2 DRIVE-CLiQ interface X500...................................................................................................... 213
10.1.3.3 X520 encoder system interface ................................................................................................ 214
10.1.3.4 X524 Electronics power supply................................................................................................. 215
10.1.3.5 Meaning of LEDs on the Sensor Module Cabinet-Mounted SMC20 ........................................ 215
10.1.4 Dimension drawing.................................................................................................................... 216

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10.1.5 Installation..................................................................................................................................217
10.1.6 Technical data............................................................................................................................218
10.2 Sensor Module External SME20................................................................................................219
10.2.1 Description .................................................................................................................................219
10.2.2 Safety Information......................................................................................................................219
10.2.3 Interface description...................................................................................................................220
10.2.3.1 Overview ....................................................................................................................................220
10.2.3.2 Connection example ..................................................................................................................220
10.2.3.3 DRIVE-CLiQ interface................................................................................................................221
10.2.3.4 Encoder system interface ..........................................................................................................222
10.2.4 Dimension drawing ....................................................................................................................223
10.2.5 Installation..................................................................................................................................223
10.2.6 Technical data............................................................................................................................224
10.3 Sensor Module External SME25................................................................................................226
10.3.1 Description .................................................................................................................................226
10.3.2 Interface description...................................................................................................................226
10.3.2.1 Overview ....................................................................................................................................226
10.3.2.2 Connection example ..................................................................................................................227
10.3.2.3 DRIVE-CLiQ interface................................................................................................................227
10.3.2.4 Encoder system interface ..........................................................................................................228
10.3.3 Dimension drawing ....................................................................................................................229
10.3.4 Installation..................................................................................................................................230
10.3.5 Technical data............................................................................................................................231
11 Accessories ........................................................................................................................................... 233
11.1 DRIVE-CLiQ cabinet bushing ....................................................................................................233
11.1.1 Description .................................................................................................................................233
11.1.2 Safety Information......................................................................................................................233
11.1.3 Interface description...................................................................................................................234
11.1.3.1 Overview ....................................................................................................................................234
11.1.4 Dimension drawing ....................................................................................................................235
11.1.5 Installation..................................................................................................................................236
11.1.6 Technical data............................................................................................................................238
11.2 DRIVE-CLiQ coupling ................................................................................................................239
11.2.1 Description .................................................................................................................................239
11.2.2 Safety information ......................................................................................................................239
11.2.3 Interface description...................................................................................................................239
11.2.3.1 Overview ....................................................................................................................................239
11.2.4 Dimension drawing ....................................................................................................................240
11.2.5 Installation..................................................................................................................................241
11.2.6 Technical data............................................................................................................................241
12 Cabinet design and EMC....................................................................................................................... 243
12.1 General information ...................................................................................................................243
12.2 Safety information ......................................................................................................................244
12.3 Directives ...................................................................................................................................244
12.4 Notes on electromagnetic compatibility (EMC)..........................................................................245
12.5 Equipotential bonding ................................................................................................................246
12.6 24 V DC supply ..........................................................................................................................247
12.6.1 General information ...................................................................................................................247
12.6.2 24 V supply and connection of the components........................................................................249

Table of contents
SINAMICS S120 Combi
20 Manual, Edition 05.2010, 6SL3097-4AV00-0BP0
12.6.3 Overcurrent protection in the 24 V solid-state circuit ................................................................ 250
12.6.4 Typical 24 V current consumption of the components.............................................................. 252
12.6.5 Selecting power supply units..................................................................................................... 254
12.7 Cable shielding and routing....................................................................................................... 255
12.7.1 General information................................................................................................................... 255
12.7.2 Signal cables and 24 V supply cables ...................................................................................... 256
12.7.3 DRIVE-CLiQ signal cables........................................................................................................ 257
12.7.4 Power cables for motor ............................................................................................................. 258
12.7.4.1 Approved power cables............................................................................................................. 258
12.7.5 Current-carrying capacity and derating factors for power cables and signal cables ................ 260
12.8 Connection system.................................................................................................................... 262
12.8.1 Connectable conductor cross-sections for spring-loaded terminals ......................................... 262
12.8.2 Connectable conductor cross-sections for screw terminals...................................................... 262
12.9 Note on control cabinet cooling................................................................................................. 264
12.9.1 General information................................................................................................................... 264
12.9.2 Ventilation.................................................................................................................................. 267
12.9.3 Dimensioning Climate Control Equipment ................................................................................ 269
12.9.4 Power loss of components in rated operation........................................................................... 270
12.9.4.1 General information................................................................................................................... 270
12.9.4.2 Power losses for SINUMERIK 828D, DC link components and supplementary system
components............................................................................................................................... 270
12.9.4.3 Power losses for S120 Combi Power Modules......................................................................... 271
12.9.4.4 Power loss for line filters and line reactors ............................................................................... 271
12.9.4.5 Electronics losses of power units.............................................................................................. 272
12.9.4.6 Losses in partial-load operation ................................................................................................ 272
13 Service and maintenance ...................................................................................................................... 275
13.1 Technical Support ..................................................................................................................... 275
13.2 Spare parts................................................................................................................................ 276
13.3 Replacing the fan ...................................................................................................................... 277
13.3.1 Replacing the Internal fan on the S120 Combi Power Module................................................. 277
13.3.2 Replacing the fan on the Motor Modules Booksize Compact................................................... 280
13.3.3 Replacing the fan on the Control Supply Module ..................................................................... 283
13.4 Cleaning the S120 Combi heat sink.......................................................................................... 284
13.5 Forming the DC link capacitors................................................................................................. 286
A Appendix................................................................................................................................................ 289
A.1 List of abbreviations .................................................................................................................. 289
Index...................................................................................................................................................... 301