Siemens Sinamics g130 Installation and operation manual

SINAMICS - Low Voltage

Engineering Manual

SINAMICS G130, G150, S120 Chassis, S120 Cabinet Modules, S150

Supplement to Catalogs D 11 and D 21.3

SINAMICS Drives

Version Edition

6.4 November

2015

Literary reference

The following title by Jens Weidauer, Richard Messer

Electrical Drives

Principles • Planning • Applications • Solutions

offers a wide-ranging, clear and comprehensible overview of modern drive systems.

The book covers all aspects of modern electrical drive systems from the viewpoint of the user. On the one hand, it is

aimed at practicians who want to understand, design, use and maintain electrical

drives. On the other, it will be a useful reference document for skilled workers,

technicians, engineers and students who wish to gain a broad general

understanding of electrical drive technology. The author explains the

fundamentals of electrical drives and their design, and goes on to describe

different applications as well as complex automation solutions. He presents the

entire spectrum of drive solutions with the relevant core applications in each

case. He gives special attention to the practice of combining multiple drives into

drive systems and to the integration of drives into automated systems.

In simple, plain language and illustrated by numerous graphics, complex

relationships are explained in a clear and coherent manner. The author

consciously avoids the use of complicated mathematical formulae, concentrating

instead on providing plain, comprehensible explanations of operating principles

and relationships. The book is designed to help readers to understand electrical

drive systems in their entirety and to solve the drive-related problems they may

encounter in their daily working lives.

Contents

1Overview

2Mechanical principles

3Electrical principles

4Fixed-speed and variable-speed drives with direct current motor

5Fixed-speed and variable-speed drives with asynchronous motor

6Servo drives

7 Stepper drives

8Electrical drives at a glance

9Fieldbuses for electrical drives

10 Process control with electrical drives

11 Motion control

12 EMC and electrical drives

13 Planning electrical drives

14 Troubleshooting on electrical drives

Print ISBN: 978-3-89578-434-7

ePDF ISBN: 978-3-89578-923-6

1st Edition 2014

Published by: Siemens Aktiengesellschaft, Berlin and Munich

Publishing house: Publicis Publishing, Erlangen

www.publicis-books.de

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sForeword

List of Contents

SINAMICS Low Voltage

Engineering Manual

Fundamental Principles and System Description

Version 6.4 – November 2015

Supplement to Catalogs D 11 and D 21.3

EMC Installation Guideline

General Engineering Information for SINAMICS

Converter Chassis Units

SINAMICS G130

Converter Cabinet Units

SINAMICS G150

General Information about Built-in and Cabinet Units

SINAMICS S120

General Information about Modular Cabinet Units

SINAMICS S120 Cabinet Modules

Converter Cabinet Units

SINAMICS S150

Disclaimer

We have checked that the contents of this document

correspond to the hardware and software described.

However, as deviations cannot be totally excluded, we are

unable to guarantee complete consistency. The information

given in this publication is reviewed at regular intervals and

any corrections that might be necessary are made in the

subsequent editions.

Subject to change without prior notice.

ãSiemens AG 2015

Description of Options for Cabinet Units

SINAMICS G150, S120 Cabinet Modules, S150

General Information about Drive Dimensioning

Motors

Foreword

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To all SINAMICS customers!

This engineering manual is supplementary to the SINAMICS Catalogs D 11 and D 21.3 and is designed to provide

additional support to users of SINAMICS converters. It focuses on drives with units in Chassis and Cabinet format in

the output power range ≥75 KW and operating in vector control mode (drive objects of vector type).

All information in this engineering manual refers to device variants equipped with the following hardware and

software:

·Power unit with Control Interface Module CIM (order number ending in 3, e.g. 6SL3310-1GE38-4AA3)

·CU320-2 Control Unit

·Firmware version 4.3 or higher

The engineering manual contains a general analysis of the fundamental principles of variable-speed drives as well as

detailed system descriptions and specific information about the following units in the SINAMICS equipment range:

·Converter Chassis Units SINAMICS G130 (Catalog D 11)

·Converter Cabinet Units SINAMICS G150 (Catalog D 11)

·Modular Chassis Units SINAMICS S120 (Catalogs D 21.3

and PM 21 / "SINAMICS S120 drive system")

·Modular Cabinet Units SINAMICS S120 Cabinet Modules (Catalog D 21.3)

·Converter Cabinet Units SINAMICS S150 (Catalog D 21.3)

This engineering manual is divided into different chapters.

The first chapter "Fundamental Principles and System Description" focuses on the physical fundamentals of electrical

variable-speed three-phase AC drives and provides general system descriptions of products in the SINAMICS range.

The second chapter “EMC Installation Guideline” gives an introduction to the subject of Electromagnetic Compatibility

(EMC), and provides all information required to engineer and install drives with the aforementioned SINAMICS

devices in an EMC-compliant manner.

The following chapters, which describe how to engineer SINAMICS G130, G150, S120 Built-in units, S120 Cabinet

Modules and S150, focus on subjects relating to specific units in more detail than the general system descriptions.

This engineering manual can and should only be viewed as a supplement to catalogs D 11, D 21.3 and PM 21 /

"SINAMICS S120 drive system". The document does not therefore contain any ordering data. The manual is

available only in electronic form in German or English.

The information of this manual is aimed at technically qualified and trained personnel. The configuring engineer is

responsible for assessing whether the information provided is sufficiently comprehensive for the application in

question and, therefore, assumes overall responsibility for the whole drive or the whole system.

The information provided in this engineering manual contains descriptions or characteristics of performance which in

case of actual use do not always apply as described, or which may change as a result of further development of the

products.

The desired performance characteristics are firmly binding only if expressly agreed upon in the contract.

Availability and technical specifications are subject to change without prior notice.

EMC warning information

The SINAMICS converter systems G130, G150, S120 Chassis units, S120 Cabinet Modules and S150 are not

designed to be connected to public networks (first environment). RFI suppression of these converter systems is

designed for industrial networks (second environment) in accordance with the EMC product standard EN 61800-3 for

variable-speed drives. If the converter systems are connected to public networks (first environment) electromagnetic

interference can occur. With additional measures (e.g. EMC-filters) the converter systems can also be connected to

public networks

Foreword

Engineering Information

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Overview of the most significant additions and modifications as compared

to Version 6.3 of this engineering manual

1.1.3.2 Interrelationships between current controller clock cycle, pulse frequency

and output frequency

àThis section has been updated owing to the introduction of stricter export regulations for frequency

converters as a result of which the maximum output frequency in the standard firmware has been

limited to 550 Hz for all the converters described in this manual since January 1, 2015 (firmware

versions ≥4.7 HF7).

With the license "High output frequency" (6SL3074-0AA02-0AA0) for SINAMICS S (which can also be

ordered as option J01 for the SINAMICS S CompactFlash card), it is now possible to increase the

maximum possible output frequency fout max for SINAMICS S to 650 Hz again. By contrast with the

standard firmware, however, the license "High output frequency" is subject to export restrictions.

1.2.6 Connection of converters to non-grounded systems (IT)

àInformation about the new VSM10 Voltage Sensing Module has been added to this section. The

jumper in connector X530 of the new VSM10 must be removed in IT systems if a very high insulation

resistance in excess of 10 MΩis required.

1.6 SINAMICS Infeeds and their properties

àAn urgent notice regarding correct control of the precharging contactor and the bypass contactor

has been added to this section.

1.16 Liquid-cooled SINAMICS S120 units

àThis section has been updated. The recommendation regarding use of the inhibitor NALCO®

TRAC100 (formerly NALCO® 00GE056) has been removed. Furthermore, the charts that specify the

pressure drop across the heat sink of the SINAMICS S120 Chassis unit as a function of the

volumetric flow rate for various recommended anti-freezes have also been revised.

3.6.6 Prevention of condensation in equipment cooled by air conditioners and climate control

systems

àMore specific information has been added to the last two paragraphs in this section. It now

includes recommendations regarding the setpoint temperature setting and the switching hysteresis of

the two-step controller as a function of the maximum predicted air humidity.

6.5 Precharging of the DC link and precharging currents

àAn urgent notice regarding the correct phase sequence and correct control of the precharging

contactor and the bypass contactor has been added to this section.

7General Information about Modular Cabinet Units SINAMICS S120 Cabinet Modules

àA description of the new liquid-cooled SINAMICS S120 Cabinet Modules has been added to this

chapter. The chapter is now structured as follows:

7.1 General (valid for air-cooled and liquid-cooled SINAMICS S120 Cabinet Modules)

7.2 Air-cooled SINAMICS S120 Cabinet Modules (revised)

7.3 Liquid-cooled SINAMICS S120 Cabinet Modules (new):

Description of the liquid-cooled S120 Cabinet Modules, dimensioning information,

Description of the cooling circuit, cooling circuit engineering.

–New liquid-cooled S120 Motor Modules in Chassis format

àThe technical data of the new liquid-cooled S120 Motor Modules in Chassis format (400 kW /

400 V / 745 A and 450 kW / 690 V / 465 A) have been incorporated in all the relevant tables.

‒Corrections

àSpelling and formatting errors have been corrected.

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List of Contents

1 Fundamental Principles and System Description ..........................................................................16

1.1 Operating principle of SINAMICS converters.............................................................................................. 16

1.1.1 General operating principle ............................................................................................................ 16

1.1.2 Pulse modulation method............................................................................................................... 16

1.1.2.1 Generation of a variable voltage by pulse-width modulation............................................................. 17

1.1.2.2 Maximum attainable output voltage with space vector modulation SVM........................................... 18

1.1.2.3 Maximum attainable output voltage with pulse-edge modulation PEM.............................................. 19

1.1.3 The pulse frequency and its influence on key system properties ...................................................... 21

1.1.3.1 Factory settings and ranges of pulse frequency settings.................................................................. 21

1.1.3.2 Interrelationships between current controller clock cycle, pulse frequency and output frequency....... 22

1.1.3.3 Influence of the pulse frequency on the inverter output current ........................................................ 24

1.1.3.4 Influence of the pulse frequency on losses and efficiency of inverter and motor................................ 24

1.1.3.5 Influence of the pulse frequency on the motor noise........................................................................ 24

1.1.3.6 Correlation between pulse frequency and motor-side options.......................................................... 26

1.1.4 Open-loop and closed-loop control modes...................................................................................... 27

1.1.4.1 General information about speed adjustment.................................................................................. 27

1.1.4.2 V/f control modes........................................................................................................................... 27

1.1.4.3 Field-oriented control modes .......................................................................................................... 29

1.1.4.4 A comparison of the key features of open-loop and closed-loop control modes ................................ 31

1.1.4.5 Load balance on mechanically coupled drives................................................................................. 31

1.1.5 Power ratings of SINAMICS converters and inverters / Definition of the output power....................... 33

1.2 Supply systems and supply system types .................................................................................................. 35

1.2.1 General ......................................................................................................................................... 35

1.2.2 Connection of converters to the supply system and protection of converters .................................... 37

1.2.3 Short Circuit Current Rating (SCCR according to UL)...................................................................... 38

1.2.4 Maximum short-circuit currents (SCCRaccording to IEC) and minimum short-circuit currents..................... 39

1.2.5 Connection of converters to grounded systems (TN or TT).............................................................. 44

1.2.6 Connection of converters to non-grounded systems (IT).................................................................. 45

1.2.7 Connection of converters to supply systems with different short-circuit powers................................. 49

1.2.8 Supply voltage variations and supply voltage dips........................................................................... 51

1.2.9 Behaviour of SINAMICS converters during supply voltage variations and dips ................................. 52

1.2.10 Permissible harmonics on the supply voltage.................................................................................. 59

1.2.11 Summary of permissible supply system conditions for SINAMICS converters................................... 60

1.2.12 Line-side contactors and circuit breakers ........................................................................................ 61

1.3 Transformers ............................................................................................................................................... 66

1.3.1 Unit transformers ........................................................................................................................... 66

1.3.1.1 General information about calculating the required apparent power of a unit transformer.................. 66

1.3.1.2 Method of calculating the required apparent power S of a unit transformer....................................... 68

1.3.2 Transformer types.......................................................................................................................... 69

1.3.3 Features of standard transformers and converter transformers........................................................ 70

1.3.4 Three-winding transformers............................................................................................................ 71

1.4 Harmonic effects on the supply system ...................................................................................................... 72

1.4.1 General ......................................................................................................................................... 72

1.4.2 Harmonic currents of 6-pulse rectifier circuits.................................................................................. 74

1.4.2.1 SINAMICS G130, G150, S120 Basic Infeed and S120 Smart Infeed in motor operation ................... 74

1.4.2.2 SINAMICS S120 Smart Infeed in regenerative operation................................................................. 76

1.4.3 Harmonic currents of 6-pulse rectifier circuits with Line Harmonics Filter.......................................... 77

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1.4.4 Harmonic currents of 12-pulse rectifier circuits.................................................................................79

1.4.5 Harmonic currents and harmonic voltages of Active Infeeds (AFE technology)..................................80

1.4.6 Standards and permissible harmonics.............................................................................................82

1.5 Line-side reactors and filters .......................................................................................................................86

1.5.1 Line reactors (line commutating reactors)........................................................................................86

1.5.2 Line Harmonics Filters (LHF and LHF compact)...............................................................................87

1.5.2.1 Operating principle of Line Harmonics Filters (LHF and LHF compact) .............................................87

1.5.2.2 Line Harmonics Filter (LHF) with separate housing (6SL3000-0J_ _ _-_AA0) ...................................88

1.5.2.3 Line Harmonics Filter compact (LHF compact) as Option L01 for SINAMICS G150...........................90

1.5.3 Line filters (radio frequency interference (RFI) suppression filter or EMC filter) .................................92

1.5.3.1 General information and standards..................................................................................................92

1.5.3.2 Line filters for the "first" environment (residential) and "second" environment (industrial)..........................95

1.5.3.3 Operating principle of line filters ......................................................................................................95

1.5.3.4 Magnitude of leakage or interference currents.................................................................................96

1.5.3.5 EMC-compliant installation..............................................................................................................97

1.6 SINAMICS Infeeds and their properties......................................................................................................100

1.6.1 Basic Infeed .................................................................................................................................100

1.6.2 Smart Infeed ................................................................................................................................102

1.6.3 Active Infeed ................................................................................................................................105

1.6.4 Comparison of the properties of the different SINAMICS Infeeds....................................................110

1.6.5 – – – ............................................................................................................................................112

1.6.6 Redundant line supply concepts....................................................................................................112

1.6.7 Permissible total cable length for S120 Infeed Modules feeding multi-motor drives .........................117

1.7 SINAMICS braking units (Braking Modules and braking resistors)...........................................................118

1.8 SINAMICS Inverters or Motor Modules.......................................................................................................119

1.8.1 Operating principle and properties.................................................................................................119

1.8.2 Drive configurations with multiple Motor Modules connected to a common DC busbar....................120

1.8.2.1 Connection of Motor Modules to the DC busbar, fuse protection and precharging...........................120

1.8.2.2 Arrangement of Motor Modules along the DC busbar.....................................................................122

1.8.2.3 Permissible dimensions and topologies of the DC busbar ..............................................................125

1.8.2.4 Short-circuit currents on the DC busbar.........................................................................................127

1.8.2.5 Maximum power rating of drive configurations at a common DC busbar .........................................129

1.9 Effects of using fast-switching power components (IGBTs) .....................................................................131

1.9.1 Increased current load on the inverter output as a result of long motor cables.................................131

1.9.2 Special issues relating to motor-side contactors and circuit breakers..............................................133

1.9.3 Increased voltage stress on the motor winding as a result of long motor cables ..............................134

1.9.4 Bearing currents caused by steep voltage edges on the motor.......................................................139

1.9.4.1 Measures for reducing bearing currents.........................................................................................140

1.9.4.1.1 EMC-compliant installation for optimized equipotential bonding in the drive system ........................141

1.9.4.1.2 Insulated bearing at the non-drive end (NDE) of the motor.............................................................145

1.9.4.1.3 Other measures............................................................................................................................145

1.9.4.2 Summary of bearing current types and counter-measures..............................................................146

1.10 Motor-side reactors and filters .................................................................................................................148

1.10.1 Motor reactors..............................................................................................................................148

1.10.1.1 Reduction of the voltage rate-of-rise dv/dt at the motor terminals....................................................148

1.10.1.2 Reduction of additional current peaks when long motor cables are used.........................................148

1.10.1.3 Permissible motor cable lengths with motor reactor(s) for single- and multi-motor drives.................149

1.10.1.4 Supplementary conditions which apply when motor reactors are used............................................152

1.10.2 dv/dt filters plus VPL and dv/dt filters compact plus VPL ................................................................153

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1.10.2.1 Design and operating principle ..................................................................................................... 153

1.10.2.2 Supplementary conditions which apply when dv/dt-filters are used ................................................ 154

1.10.3 Sine-wave filters .......................................................................................................................... 155

1.10.3.1 Design and operating principle ..................................................................................................... 155

1.10.3.2 Supplementary conditions which apply when sine-wave filters are used......................................... 156

1.10.4 Comparison of the properties of the motor-side reactors and filters................................................ 157

1.11 – – –.......................................................................................................................................................... 159

1.12 Power cycling capability of IGBT modules and inverter power units ..................................................... 159

1.12.1 General ....................................................................................................................................... 159

1.12.2 IGBT module with cyclically alternating current load...................................................................... 159

1.12.3 Dimensioning of the power units for operation at low output frequencies ........................................ 160

1.13 Load duty cycles...................................................................................................................................... 164

1.13.1 General ....................................................................................................................................... 164

1.13.2 Standard load duty cycles ............................................................................................................ 164

1.13.3 Free load duty cycles ................................................................................................................... 165

1.13.4 Thermal monitoring of the power unit............................................................................................ 179

1.13.5 Operation of converters at increased pulse frequency ................................................................... 179

1.14 Efficiency of SINAMICS converters at full load and at partial load......................................................... 183

1.14.1 Converter efficiency at full load..................................................................................................... 183

1.14.2 Converter efficiency at partial load................................................................................................ 184

1.14.2.1 – – –............................................................................................................................................ 184

1.14.2.2 Partial load efficiency of S120 Basic Line Modules........................................................................ 184

1.14.2.3 Partial load efficiency of S120 Smart Line Modules ....................................................................... 185

1.14.2.4 Partial load efficiency of S120 Active Line Modules + Active Interface Modules.............................. 185

1.14.2.5 Partial load efficiency of S120 Motor Modules............................................................................... 186

1.14.2.6 Partial load efficiency of G130 / G150 converters.......................................................................... 187

1.14.2.7 Partial load efficiency of S150 converters...................................................................................... 190

1.15 Parallel connections of converters.......................................................................................................... 193

1.15.1 General ....................................................................................................................................... 193

1.15.2 Parallel connections of SINAMICS converters............................................................................... 193

1.15.3 Parallel connection of S120 Basic Line Modules ........................................................................... 195

1.15.4 Parallel connection of S120 Smart Line Modules........................................................................... 197

1.15.5 Parallel connection of S120 Active Line Modules .......................................................................... 199

1.15.6 Parallel connection of S120 Motor Modules .................................................................................. 201

1.15.7 Admissible and inadmissible winding systems for parallel connections of converters...................... 203

1.16 Liquid-cooled SINAMICS S120 units........................................................................................................ 206

1.16.1 General ....................................................................................................................................... 206

1.16.2 Design of the liquid-cooled SINAMICS S120 units......................................................................... 206

1.16.3 Cooling circuit and coolant requirements....................................................................................... 207

1.16.4 Example of a closed cooling circuit for liquid-cooled SINAMICS S120 units.................................... 210

1.16.5 Example of an open cooling circuit for liquid-cooled SINAMICS S120 units.................................... 210

1.16.6 Example of coolant temperature control for condensation prevention............................................. 211

1.16.7 Information about cooling circuit configuration............................................................................... 214

1.16.8 Information about cabinet design.................................................................................................. 223

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2 EMC Installation Guideline ............................................................................................................227

2.1 Introduction ................................................................................................................................................227

2.1.1 General........................................................................................................................................227

2.1.2 EC Directives ...............................................................................................................................227

2.1.3 CE marking..................................................................................................................................227

2.1.4 EMC Directive..............................................................................................................................228

2.1.5 EMC product standard EN 61800-3...............................................................................................228

2.2 Fundamental principles of EMC .................................................................................................................230

2.2.1 Definition of EMC .........................................................................................................................230

2.2.2 Interference emissions and interference immunity..........................................................................231

2.3 The frequency converter and its EMC........................................................................................................231

2.3.1 The frequency converter as a source of interference......................................................................231

2.3.2 The frequency converter as a high-frequency source of interference ..............................................232

2.3.3 The frequency converter as a low-frequency source of interference................................................236

2.3.4 The frequency converter as potentially susceptible equipment .......................................................237

2.3.4.1 Methods of influence.....................................................................................................................237

2.3.4.1.1 Conductive coupling .....................................................................................................................237

2.3.4.1.2 Capacitive coupling ......................................................................................................................238

2.3.4.1.3 Inductive coupling.........................................................................................................................239

2.3.4.1.4 Electromagnetic coupling (radiative coupling) ................................................................................240

2.4 EMC-compliant installation ........................................................................................................................240

2.4.1 Zone concept within the converter cabinet.....................................................................................241

2.4.2 Converter cabinet structure...........................................................................................................242

2.4.3 Cables inside the converter cabinet...............................................................................................242

2.4.4 Cables outside the converter cabinet.............................................................................................243

2.4.5 Cable shields................................................................................................................................243

2.4.6 Equipotential bonding in the converter cabinet, in the drive system, and in the plant .......................243

2.4.7 Examples for installation...............................................................................................................245

2.4.7.1 EMC-compliant installation of a SINAMICS G150 converter cabinet unit.........................................245

2.4.7.2 EMC-compliant construction/installation of a cabinet with a SINAMICS G130 Chassis unit..............246

2.4.7.3 EMC-compliant cable routing on the plant side on cable racks and in cable ducts...........................247

3 General Engineering Information for SINAMICS...........................................................................249

3.1 Overview of documentation .......................................................................................................................249

3.2 Safety-integrated / Drive-integrated safety functions ................................................................................254

3.2.1 Safety Integrated Basic Functions Safe Torque Off (STO) und Safe Stop 1 (SS1)...........................254

3.3 Precharging intervals of the DC link ..........................................................................................................258

3.3.1 SINAMICS Booksize units.............................................................................................................258

3.3.2 SINAMICS Chassis units ..............................................................................................................258

3.4 Operator Panels..........................................................................................................................................258

3.4.1 Basic Operator Panel (BOP20) .....................................................................................................258

3.4.2 Advanced Operator Panel (AOP30)...............................................................................................258

3.5 CompactFlash Cards for CU320-2 Control Units .......................................................................................260

3.6 Cabinet design and air conditioning ..........................................................................................................261

3.6.1 Directives and standards ..............................................................................................................261

3.6.2 Physical fundamental principles ....................................................................................................263

3.6.3 Cooling air requirements and air opening cross-sections in the cabinet ..........................................265

3.6.4 Required ventilation clearances ....................................................................................................267

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3.6.5 Required partitioning.................................................................................................................... 269

3.6.6 Prevention of condensation in equipment cooled by air conditioners and climate control systems... 270

3.7 Changing the power block on air-cooled power units in Chassis format................................................. 271

3.8 Replacement of SIMOVERT P and SIMOVERT A converter ranges by SINAMICS.................................... 272

3.8.1 General ....................................................................................................................................... 272

3.8.2 Replacement of converters in SIMOVERT P 6SE35/36 and 6SC36/37 ranges by SINAMICS......... 272

3.8.3 Replacement of converters in SIMOVERT A range by SINAMICS ................................................. 274

4 Converter Chassis Units SINAMICS G130 ....................................................................................276

4.1 General information................................................................................................................................... 276

4.2 Rated data of converters for drives with low demands on control performance...................................... 279

4.3 Connection diagram of the Power Module ................................................................................................ 285

4.4 Incorporating different loads into the 24 V supply.................................................................................... 286

4.5 Factory settings (defaults) of customer interface on SINAMICS G130 ..................................................... 287

4.6 Cable cross-sections and connections on SINAMICS G130 Chassis Units.............................................. 292

4.7 Precharging of the DC link and precharging currents .............................................................................. 292

4.8 Line-side components ............................................................................................................................... 294

4.8.1 Line fuses.................................................................................................................................... 294

4.8.2 Line reactors................................................................................................................................ 294

4.8.3 Line Harmonics Filters ................................................................................................................. 295

4.8.4 Line filters.................................................................................................................................... 295

4.9 Components at the DC link........................................................................................................................ 296

4.9.1 Braking units................................................................................................................................ 296

4.10 Load-side components and cables.......................................................................................................... 300

4.10.1 Motor reactors ............................................................................................................................. 300

4.10.2 dv/dt filters plus VPL .................................................................................................................... 300

4.10.3 Sine-wave filters .......................................................................................................................... 300

4.10.4 Maximum connectable motor cable lengths................................................................................... 300

5 Converter Cabinet Units SINAMICS G150.....................................................................................302

5.1 General information................................................................................................................................... 302

5.2 Rated data of converters for drives with low demands on control performance...................................... 302

5.3 Factory settings (defaults) of customer interface on SINAMICS G150 with TM31.................................... 309

5.4 Cable cross-sections and connections on SINAMICS G150 Cabinet Units .............................................. 311

5.4.1 Recommended and max. possible cable cross-sections for line and motor connections ................. 311

5.4.2 Required cable cross-sections for line and motor connections ....................................................... 313

5.4.3 Grounding and PE conductor cross-section .................................................................................. 314

5.5 Precharging of the DC link and precharging currents .............................................................................. 315

5.6 Line-side components ............................................................................................................................... 317

5.6.1 Line fuses.................................................................................................................................... 317

5.6.2 Line reactors................................................................................................................................ 317

5.6.3 Line Harmonics Filters ................................................................................................................. 318

5.6.4 Line filters.................................................................................................................................... 318

5.7 Components at the DC link........................................................................................................................ 319

5.7.1 Braking units................................................................................................................................ 319

5.8 Load-side components and cables............................................................................................................ 323

5.8.1 Motor reactors ............................................................................................................................. 323

5.8.2 dv/dt filters plus VPL and dv/dt filters compact plus VPL................................................................ 323

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5.8.3 Sine-wave filters...........................................................................................................................323

5.8.4 Maximum connectable motor cable lengths...................................................................................324

5.9 SINAMICS G150 parallel converters (SINAMICS G150 power extension)..................................................324

5.9.1 6-pulse operation of SINAMICS G150 parallel converters ..............................................................327

5.9.2 12-pulse operation of SINAMICS G150 parallel converters ............................................................328

5.9.3 Operation at motors with electrically isolated and with common winding systems............................329

5.9.4 Special features to note when precharging SINAMICS G150 parallel converters.............................331

5.9.5 Overview of SINAMICS G150 parallel converters ..........................................................................334

6 General Information about Built-in and Cabinet Units SINAMICS S120 ......................................335

6.1 General .......................................................................................................................................................335

6.1.1 Assignment table..........................................................................................................................335

6.2 Control properties ......................................................................................................................................335

6.2.1 Performance features of the CU320-2 Control Unit ........................................................................335

6.2.2 Control properties / definitions.......................................................................................................337

6.2.3 Control properties of the CU320-2 Control Unit..............................................................................338

6.2.4 Determination of the required control performance of the CU320-2 Control Unit..............................345

6.3 Rated data, permissible output currents, maximum output frequencies ..................................................348

6.3.1 Permissible output currents and maximum output frequencies .......................................................348

6.3.2 Ambient temperatures > 40°C and installation altitudes > 2000 m ..................................................349

6.4 DRIVE-CLiQ ................................................................................................................................................351

6.4.1 Basic information..........................................................................................................................351

6.4.2 Determination of component cabeling............................................................................................352

6.4.3 DRIVE-CLiQ cables supplied with the units ...................................................................................353

6.4.4 Cable installation..........................................................................................................................354

6.5 Precharging of the DC link and precharging currents ...............................................................................357

6.5.1 Basic Infeed .................................................................................................................................357

6.5.2 Smart Infeed ................................................................................................................................359

6.5.3 Active Infeed ................................................................................................................................361

6.6 Checking the maximum DC link capacitance.............................................................................................363

6.6.1 Basic information..........................................................................................................................363

6.6.2 Capacitance values ......................................................................................................................364

6.7 Connection of Motor Modules to a common DC busbar............................................................................368

6.7.1 Direct connection to the DC busbar...............................................................................................368

6.8 Braking Modules / External braking resistors............................................................................................369

6.8.1 Braking Modules for power units in Chassis format........................................................................369

6.8.2 Braking resistors for power units in Chassis format........................................................................372

6.8.3 SINAMICS S120 Motor Modules as 3-phase Braking Modules.......................................................373

6.9 Maximum connectable motor cable lengths ..............................................................................................378

6.9.1 Booksize units..............................................................................................................................378

6.9.2 Chassis units................................................................................................................................379

6.10 Checking the total cable length for multi-motor drives ...........................................................................380

6.11 Parallel connections of Motor Modules....................................................................................................381

6.11.1 General........................................................................................................................................381

6.11.2 Minimum motor cable lengths for motors with common winding system..........................................381

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7 General Information about Modular Cabinet Units SINAMICS S120 Cabinet Modules...............382

7.1 General ....................................................................................................................................... 382

7.2 Air-cooled SINAMICS S120 Cabinet Modules............................................................................................ 383

7.2.1 General configuring process .................................................................................................................. 383

7.2.2 Dimensioning information for air-cooled S120 Cabinet Modules........................................................... 384

7.2.2.1 Derating data of air-cooled S120 Cabinet Modules........................................................................ 384

7.2.2.1.1 Derating data for S120 Cabinet Modules with power units in Chassis format.................................. 384

7.2.2.1.2 Derating data for S120 Cabinet Modules with power units in Booksize format ................................ 385

7.2.2.2 Degrees of protection of air-cooled S120 Cabinet Modules............................................................ 386

7.2.2.3 Required DC busbar cross-sections and maximum short-circuit currents ....................................... 386

7.2.2.4 Required cable cross-sections for line and motor connections ....................................................... 387

7.2.2.5 Cooling air requirements of air-cooled S120 Cabinet Modules ....................................................... 389

7.2.2.6 Auxiliary power requirements ....................................................................................................... 390

7.2.2.7 Line reactors................................................................................................................................ 398

7.2.2.8 Line Harmonics Filter ................................................................................................................... 399

7.2.2.9 Line filters.................................................................................................................................... 399

7.2.2.10 Parallel configuration.................................................................................................................... 400

7.2.2.11 Weights of S120 Cabinet Modules................................................................................................ 401

7.2.3 Information about equipment handling of air-cooled units.................................................................... 404

7.2.3.1 Customer terminal block -X55 ...................................................................................................... 404

7.2.3.2 Customer terminal blocks -X55.1 and -X55.2 ................................................................................ 406

7.2.3.3 Auxiliary voltage supply system.................................................................................................... 407

7.2.3.4 DRIVE-CLiQ wiring...................................................................................................................... 409

7.2.3.5 Erection of cabinets ..................................................................................................................... 410

7.2.3.6 Examples of Cabinet Modules arrangements................................................................................ 410

7.2.3.7 Door opening angle...................................................................................................................... 411

7.2.4 Line Connection Modules ....................................................................................................................... 412

7.2.4.1 Design......................................................................................................................................... 412

7.2.4.2 Planning recommendations, special features ................................................................................ 413

7.2.4.3 Assignment to the rectifiers / Line Modules ................................................................................... 413

7.2.4.4 Parallel connections..................................................................................................................... 414

7.2.4.5 DC busbar................................................................................................................................... 415

7.2.4.6 Circuit breakers ........................................................................................................................... 415

7.2.4.7 Short-circuit strength.................................................................................................................... 417

7.2.5 Basic Line Modules................................................................................................................................. 418

7.2.5.1 Design......................................................................................................................................... 418

7.2.5.2 DC link fuses ............................................................................................................................... 419

7.2.5.3 Parallel connections of Basic Line Modules................................................................................... 419

7.2.6 Smart Line Modules ................................................................................................................................ 420

7.2.6.1 Design......................................................................................................................................... 420

7.2.6.2 DC link fuses ............................................................................................................................... 421

7.2.6.3 Parallel connections of Smart Line Modules.................................................................................. 421

7.2.7 Active Line Modules + Active Interface Modules.................................................................................... 422

7.2.7.1 Design......................................................................................................................................... 422

7.2.7.2 DC Link fuses .............................................................................................................................. 424

7.2.7.3 Parallel connections of Active Line Modules + Active Interface Modules ........................................ 424

7.2.8 Motor Modules ........................................................................................................................................ 426

7.2.8.1 Design......................................................................................................................................... 426

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7.2.8.2 DC link fuses................................................................................................................................426

7.2.8.3 Parallel connections of Motor Modules ..........................................................................................427

7.2.8.3.1 General........................................................................................................................................427

7.2.8.3.2 Minimum motor cable lengths for motors with common winding system..........................................427

7.2.9 Booksize Base Cabinet / Booksize Cabinet Kits .....................................................................................428

7.2.9.1 Design .........................................................................................................................................428

7.2.9.2 Booksize Base Cabinet.................................................................................................................428

7.2.9.3 Booksize Cabinet Kits...................................................................................................................428

7.2.9.4 DC link fuses................................................................................................................................429

7.2.9.5 Planning recommendations, special features.................................................................................429

7.2.10 Central Braking Modules .......................................................................................................................433

7.2.10.1 Design .........................................................................................................................................433

7.2.10.2 Position in the DC link configuration..............................................................................................436

7.2.10.3 DC Link fuses...............................................................................................................................436

7.2.10.4 Parallel configuration of Central Braking Modules ..........................................................................436

7.2.10.5 Braking resistor ............................................................................................................................436

7.2.11 Auxiliary Power Supply Modules...........................................................................................................438

7.2.11.1 Design .........................................................................................................................................438

7.3 Liquid-cooled SINAMICS S120 Cabinet Modules.......................................................................................440

7.3.1 General configuring process...................................................................................................................440

7.3.2 Dimensioning information for liquid-cooled SINAMICS S120 Cabinet Modules.....................................441

7.3.2.1 Degrees of protection of liquid-cooled S120 Cabinet Modules ........................................................441

7.3.2.2 Required DC busbar cross-sections and maximum short-circuit currents........................................441

7.3.2.3 Required cable cross-sections for line and motor connections........................................................442

7.3.2.4 Cooling air requirements of liquid-cooled S120 Cabinet Modules....................................................444

7.3.2.5 Auxiliary power requirements........................................................................................................445

7.3.2.6 Line reactors ................................................................................................................................448

7.3.2.7 Line Harmonics Filter....................................................................................................................449

7.3.2.8 Line filters ....................................................................................................................................449

7.3.2.9 Parallel configuration....................................................................................................................450

7.3.2.10 Weights of S120 Cabinet Modules ................................................................................................451

7.3.3 Information about equipment handling of liquid-cooled units................................................................452

7.3.3.1 Customer terminal block ...............................................................................................................452

7.3.3.2 Auxiliary voltage supply system.....................................................................................................452

7.3.3.3 DRIVE-CLiQ wiring.......................................................................................................................452

7.3.3.4 Erection of cabinets......................................................................................................................453

7.3.3.5 Examples of Cabinet Modules arrangements.................................................................................454

7.3.3.6 Door opening angle ......................................................................................................................454

7.3.4 Information about the cooling circuit and the cooling circuit configuration..........................................455

7.3.4.1 Design of the liquid-cooled Cabinet Modules .................................................................................455

7.3.4.2 Required converter-side deionized water circuit.............................................................................455

7.3.4.3 Required plant-side raw water circuit.............................................................................................457

7.3.4.4 Derating data of liquid-cooled S120 Cabinet Modules ....................................................................457

7.3.4.5 Information about cooling circuit configuration ...............................................................................458

7.3.4.6 Procedure of cooling circuit configuration ......................................................................................460

7.3.4.7 Example of a cooling circuit configuration......................................................................................462

7.3.5 Basic Line Connection Modules..............................................................................................................466

7.3.5.1 Design .........................................................................................................................................466

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7.3.5.2 DC link fuses ............................................................................................................................... 468

7.3.5.3 Parallel connections of Basic Line Connection Modules ................................................................ 468

7.3.6 Active Line Connection Modules............................................................................................................ 469

7.3.6.1 Design......................................................................................................................................... 469

7.3.6.2 DC link fuses ............................................................................................................................... 471

7.3.6.3 Parallel connections of Active Line Connection Modules ............................................................... 471

7.3.7 Motor Modules ........................................................................................................................................ 472

7.3.7.1 Design......................................................................................................................................... 472

7.3.7.2 DC link fuses ............................................................................................................................... 473

7.3.7.3 Parallel connections of Motor Modules.......................................................................................... 474

7.3.7.3.1 General ....................................................................................................................................... 474

7.3.7.3.2 Minimum motor cable lengths for motors with common winding system ......................................... 474

7.3.8 Auxiliary Power Supply Modules (available soon) ................................................................................. 475

7.3.8.1 Design......................................................................................................................................... 475

7.3.9 Heat Exchanger Modules........................................................................................................................ 476

7.3.9.1 Design and operating principle ..................................................................................................... 476

7.3.10 Braking Modules ................................................................................................................................... 478

8 Converter Cabinet Units SINAMICS S150 .....................................................................................479

8.1 General information................................................................................................................................... 479

8.2 Rated data and continuous operation of the converters........................................................................... 480

8.3 Factory settings (defaults) of customer interface on SINAMICS S150 with TM31 .................................... 484

8.4 Cable cross-sections and connections on SINAMICS S150 cabinet units................................................ 486

8.4.1 Recommended and max. possible cable cross-sections for line and motor connections ................. 486

8.4.2 Required cable cross-sections for line and motor connections ....................................................... 487

8.4.3 Grounding and PE conductor cross-section .................................................................................. 488

8.5 Precharging of the DC link and precharging currents .............................................................................. 488

8.6 Load side components .............................................................................................................................. 489

8.6.1 Line fuses.................................................................................................................................... 489

8.6.2 Line filters.................................................................................................................................... 490

8.7 Components at the DC link........................................................................................................................ 490

8.7.1 Braking units................................................................................................................................ 490

8.8 Load-side components and cables............................................................................................................ 490

8.8.1 Motor reactors ............................................................................................................................. 490

8.8.2 dv/dt filters plus VPL .................................................................................................................... 491

8.8.3 Sine-wave filters .......................................................................................................................... 491

8.8.4 Maximum connectable motor cable lengths................................................................................... 491

8.9 Option L04 (Infeed Module dimensioned one rating class lower)............................................................. 492

9 Description of Options for Cabinet Units......................................................................................494

9.1 Option G33 (CBE20 Communication Board) ................................................................................ 494

9.2 Option G51 – G54 (Terminal Module TM150)............................................................................... 495

9.3 Option K82 (Terminal module for controlling the “Safe Torque Off” and “Safe Stop1” functions)..... 497

9.4 Options K90 (CU320-2 DP), K95 (CU320-2 PN) and K94 (Performance expansion)...................... 502

9.5 Option L08 (Motor reactor) / L09 (2 motor reactors in series)........................................................ 503

9.6 Option L25 (Circuit breaker in a withdrawable unit design)............................................................ 503

9.7 Option L34 (Output-side circuit breaker)....................................................................................... 504

9.8 Option L37 (DC interface incl. precharging circuit)........................................................................ 505

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9.9 Option M59 (Closed cabinet doors) ..............................................................................................505

9.10 Option Y11 (Factory assembly into transport units)........................................................................506

10 General Information about Drive Dimensioning .........................................................................508

10.1 General........................................................................................................................................508

10.2 Drives with quadratic load torque ..................................................................................................509

10.3 Drives with constant load torque ...................................................................................................511

10.4 Permissible motor-converter combinations ....................................................................................512

10.5 Drives with permanent-magnet three-phase synchronous motors...................................................513

11 Motors...........................................................................................................................................519

11.1 SIMOTICS SD & SIMOTICS TN series N-compact 1LA8 self-cooled asynchronous motors ............519

11.2 SIMOTICS TN series N-compact 1PQ8 forced-cooled asynchronous motors..................................519

11.3 SIMOTICS TN series N-compact 1LL8 open-circuit self-cooled asynchronous motors ....................520

11.4 Converter-optimized SIMOTICS FD asynchronous motors.............................................................520

11.5 SIMOTICS TN series H-compact PLUS modular asynchronous motors..........................................524

11.6 SIMOTICS M compact asynchronous motors ................................................................................525

11.7 SIMOTICS HT series HT-direct 1FW4 synchronous motors with permanent magnets.....................525

11.8 Special insulation for higher line supply voltages at converter-fed operation ...................................526

11.9 Bearing currents...........................................................................................................................527

11.10 Motor protection ...........................................................................................................................527

Fundamental Principles and System Description

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1 Fundamental Principles and System Description

1.1 Operating principle of SINAMICS converters

1.1.1 General operating principle

The converters in the SINAMICS product range are PWM converters with a voltage-source DC link. At the input side,

the converter consists of a rectifier (shown in the schematic sketch as a thyristor rectifier) which is supplied with a

constant voltage VLine and a constant frequency fLine from a three-phase supply. The rectifier produces a constant DC

voltage VDCLink, i.e. the DC link voltage, which is smoothed by the DC link capacitors. The 2-level IGBT inverter on

the output side converts the DC link voltage to a three-phase system with a variable voltage VMotor and variable

frequency fMotor. This process operates according to the principle of pulse-width modulation PWM. By varying the

voltage and the frequency, it is possible to vary the speed of the connected three-phase motor continuously and

virtually without losses.

Block diagram of a PWM converter with voltage-source DC link

1.1.2 Pulse modulation method

The power semiconductors of the IGBT inverter (IGBT = Insulated Gate Bipolar Transistor) are high-speed, electronic

switches which connect the converter outputs to the positive or negative pole of the DC link voltage. The duration of

the gating signals in the individual inverter phases and the magnitude of the DC link voltage thus clearly determine

the output voltage and therefore also the voltage at the connected motor.

Fundamental Principles and System Description

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If we consider all three phases, there is a total of 2³= 8 switching states in the inverter, and the effect of these states

in the motor can be defined by voltage phasors.

Switching states of the

inverter

Phase

+ - -

+ + -

- + -

- + +

- - +

+ - +

+ + +

- - -

If, for example, phase L1 is connected to the positive DC link voltage, and phases L2 and L3 to the negative voltage

so as to produce switching state V1, the resultant voltage phasor points in the direction of motor phase L1 and is

designated phase I. The length of this phasor is determined by the DC link voltage.

Representation of resultant motor voltages as phasor

If the switching state changes from V1to V2, then the voltage phasor rotates clockwise by an angle of 60°el. due to

the change in potential at terminal L2. The length of the phasor remains unchanged.

In the same way, the relevant voltage phasors are produced by switching combinations V3to V

. Switching

combinations V7and V8produce the same potential at all motor terminals. These two combinations therefore produce

voltage phasors of "zero" length (zero voltage phasor).

1.1.2.1 Generation of a variable voltage by pulse-width modulation

Voltage and frequency must be specified in a suitable way for a certain operating state of the motor, characterized by

speed and torque. Ideally, this corresponds to control of the voltage vector V(wt) on a circular path with the speed of

rotation w= 2 *p*f and adjusted absolute value. This is achieved through modulation of the actual settable voltage

space vectors (pulse-width modulation). In this way, the momentary value V(wt) is formed by pulses of the adjacent,

actual settable voltage space vectors and the voltage zero.

The solid angle is set directly by varying the ratio of the ON durations (pulse-width) of adjacent voltage vectors, the

desired absolute value by varying the ON duration of the zero voltage vector. This method of generating gating

signals is called space vector modulation SVM. It is used in all units described in this engineering manual. Space

vector modulation provides sine-modulated pulse patterns.

Fundamental Principles and System Description

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The following diagram illustrates how the voltages in phases L1 and L2 plus output voltage VL1-L2 (phase-to-phase

voltage) are produced by pulse-width modulation or space vector modulation and shows their basic time

characteristics. The frequency with which the IGBTs in the inverter phases are switched on and off is referred to as

the pulse frequency or clock frequency of the inverter.

Timing of the gating signal sequence for the IGBTs in the inverter phases L1 and L2 plus the associated output voltage

(phase-to-phase voltage) VL1-L2. The amplitude of the voltage pulses corresponds to the DC link voltage.

The diagram below shows the time characteristic (in blue) of one of the three output voltages of the inverter (phase-

to-phase voltage) and the resulting current (in black) generated in one of the three motor phases when a standard

asynchronous motor with a rated frequency of 50 Hz or 60 Hz is used and the inverter is operating with a pulse

frequency of 1.25 kHz. The diagram shows that the smoothing effect of the motor inductances causes the motor

current to be virtually sinusoidal, despite the fact that the motor is supplied with a square-wave pulse pattern.

Motor voltage (phase-to-phase) and motor current with space vector modulation

1.1.2.2 Maximum attainable output voltage with space vector modulation SVM

Space vector modulation SVM generates pulse patterns which approximate an ideal sinusoidal motor voltage through

voltage pulses with constant amplitude and corresponding pulse-duty factor. The peak value of the maximum

(fundamental) voltage that can be attained in this way corresponds to the amplitude of the DC link voltage VDCLink.

Thus the theoretical maximum motor voltage with space vector modulation which results is:

DCLink

SVM VV ×= 2

max

The amplitude of the DC link voltage VDCLink is determined by the method of line voltage rectification. With line-

commutated rectifiers used with SINAMICS G130 and G150 and also with S120 Basic Line Modules, it averages

1.41*VLine with no load, 1.35*VLine with partial load and 1.32*VLine.with full load. Thus with the true DC link voltage

amplitude of VDCLink ≈ 1.32*VLine at full load, the motor voltage theoretically attainable at full load with space vector

modulation without overmodulation is:

VSVM max = 0.935 *VLine .

Fundamental Principles and System Description

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As a result of voltage drops in the converter and minimum pulse times and interlock times in the gating unit

responsible for generating the IGBT gating pulse pattern, the values in reality are lower. In practice, therefore, the

value for space vector modulation without overmodulation must be assumed to be as follows:

VSVM max ≈0.92 *VLine

This value applies precisely to pulse frequencies of 2.0 kHz or 1.25 kHz according to the factory setting. At higher

pulse frequencies, it decreases by approximately 0.5 % per kHz.

1.1.2.3 Maximum attainable output voltage with pulse-edge modulation PEM

It is possible to increase the inverter output voltage above the values attained with space vector modulation (SVM) by

pulsing only at the edges of the fundamental-wave period rather than over the entire fundamental-wave period. This

process is referred to as pulse-edge modulation (PEM). The basic waveform of the motor voltage is then as shown

below.

Motor voltage with pulse-edge modulation PEM

The maximum possible output voltage is attained when clocking is performed with the fundamental frequency only,

i.e. when "pulsing" ceases altogether. The output voltage then consists of 120° rectangular blocks with the amplitude

of the DC link voltage. The fundamental frequency RMS value of the output voltage can then be calculated as:

LineLineDCLink

rect VVVV ×=××=×= 03.132.1

So it is possible with pure rectangular modulation to achieve a motor voltage which is slightly higher than the line

voltage. However, the motor voltage then has an unsuitable harmonic spectrum which causes major stray losses in

the motor and utilizes the motor inefficiently. It is for this reason that pure square-wave modulation is not utilized on

SINAMICS converters.

The pulse-edge modulation method used on SINAMICS converters permits a maximum output voltage which is only

slightly lower than the line voltage, even when allowance is made for voltage drops in the converter:

VPEM max ≈0.97 *VLine

The pulse-edge modulation method uses optimized pulse patterns which cause only minor harmonic currents and

therefore utilize the connected motor very efficiently. Commercially available standard asynchronous motors for

50 Hz or 60 Hz operation utilized according to temperature class 130 (previously temperature class B) in operation

directly on line can be utilized according to temperature class 155 (previously temperature class F) when operated

with pulse-edge modulation at the nominal operating point up to rated torque.

Pulse-edge modulation is available as standard in vector control mode (drive object of vector type) on all SINAMICS

units described in this engineering manual:

·SINAMICS G130 *)Chassis

·SINAMICS G150 *)Cabinets

·SINAMICS S150 *)Cabinets

·SINAMICS S120 *)Motor Modules / Chassis format

·SINAMICS S120 *)Motor Modules / Cabinet Modules format

For SINAMICS G130 and G150 converters, the modulator mode (parameter p1802) is automatically preset to value 9

(pulse-edge modulation) since "Pumps and fans" is the default technological application (parameter p0500 = 1). This

is because SINAMICS G converters are predominantly deployed in conjunction with asynchronous motors without

Fundamental Principles and System Description

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speed encoder as independent single drives for applications with simple control requirements. At a low output

frequency and low depth of modulation (output voltage < 92 % of input voltage), these converters utilize space vector

modulation SVM and switch over to pulse-edge modulation PEM automatically if the depth of modulation required at

higher output frequencies is so high that it can no longer be provided by space vector modulation SVM (output

voltage > 92 % of input voltage). The minor irregularities in the torque characteristic caused by transient phenomena

during transition between different modulation systems are virtually irrelevant for applications with simple control

requirements of the kind mentioned above.

VLine

fMot

fMot-rated

00,5 1,0

VMot

60%

40%

20%

90%

100%

SVM

PEM1PEM2

Constant-flux range Field-weakening range

V ~ f

V = const

SVM

SVM + PEM

V = const

V ~ f

Maximum attainable motor voltage with space vector modulation SVM and pulse-edge modulation PEM

For SINAMICS S120 Motor Modules and SINAMICS S150 converters, the modulator mode (parameter p1802) is

automatically preset to the value 4 (space vector modulation without overmodulation) in vector control mode because

the default technological application is "Standard drive vector" (parameter p0500 = 0). In this case, these units utilize

only space vector modulation SVM because, and this applies particularly to SINAMICS S120 Motor Modules, they

are predominantly used in coordinated multi-motor drive systems with sophisticated control technology which

demand very high control quality (e.g. strip finishing lines, paper-making machines and foil-drawing machines). These

types of application can rarely tolerate the minor irregularities in the torque characteristic caused by transient

phenomena during transition between different modulation systems. If SINAMICS S120 Motor Modules and

SINAMICS S150 converters are required to operate with pulse-edge modulation PEM, the modulator mode

(parameter p1802) must be set to 9 (pulse-edge modulation) during commissioning.

Basically, it would also be possible to achieve depths of modulation or output voltages in excess of 92 % through

overmodulation of the space vector modulation SVM (by setting parameter p1802 to values 0, 1, 2, 5, 6). While it is

possible by this method to prevent the slight irregularities in the torque characteristic on transition between

modulation systems, it also causes the harmonics spectrum in the motor current to increase, resulting in higher

torque ripples and higher motor losses. With a very high level of overmodulation (maximum modulation depth setting

in parameter p1803 > approx. 103 %), the control quality decreases significantly. Pulse-edge modulation PEM with its

optimized pulse patterns therefore offers obvious advantages in this case, as it enables a high depth of modulation

(high output voltage) combined with good drive behavior (in terms of torque accuracy and motor losses) to be

achieved.

*)Exceptions regarding the use of pulse-edge modulation:

Converters with output-side sine-wave filter. Pulse-edge modulation cannot be selected under these conditions.

If either a Basic or Smart Infeed is used to supply the inverter, the following formulae apply for the DC link voltage at

full load: VDCLink ≈1.32 • VLine resp. VDCLink = 1.30 • VLine. In this case, the maximum output voltage is limited to 85 %

of the line input voltage for units with a supply voltage of 380 V to 480 V 3AC and to 83 % for units with a supply

voltage of 500 V to 600 V 3AC.

If an Active Infeed is used to supply the inverter, the following formula applies to the DC link voltage because the

Active Infeed utilizes a step-up converter function: VDCLink > 1.42 • VLine (factory setting: VDCLink = 1.5 • VLine). This

means that the maximum output voltage even without pulse-edge modulation can correspond to 100 % of the line

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