Siemens SINAMICS S120 Technical Document

sinamics
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SINAMICS S120
Chassis Power Units Liquid Cooled
Equipment Manual 12/2007 Edition

System Overview
1
Line-Side Power
Components
2
Power Modules
3
Line Modules
4
Motor Modules
5
Motor-Side Power
Components
6
Cabinet Design and EMC
7
Cooling circuit and coolant
properties
8
Maintenance and servicing
9
List of Abbreviations
10
SINAMICS S120
Chassis Power Units
Liquid Cooled
Equipment Manual
(GH7), Edition 12/2007
6SL3097-2AM00-0BP4

Safety guidelines
This Manual contains information which you should carefully observe to ensure your own personal safety and the
prevention of material damage. Notices which are relevant to your own personal safety are highlighted by a safety
alert symbol; notices which are relevant only to equipment and property damage have no safety alert symbol. The
warnings appear in decreasing order of risk as given below.
Danger
"Danger" indicates that death or severe personal injury will result if proper precautions are not taken.
Alarm
"Warning" indicates that death or severe personal injury can result if proper precautions are not taken.
Caution
"Caution" with a warning triangle indicates that minor personal injury can result if proper precautions are not
taken.
Caution
"Caution" without a warning triangle indicates that material damage can result if proper precautions are not taken.
Notice
"Important" indicates that an unwanted result or situation can result if the appropriate advice is not taken into
account.
If several hazards of different degrees occur, the hazard with the highest degree must always be given priority. A
warning notice accompanied by a safety alert symbol indicating a risk of bodily injury can also indicate a risk of
property damage.
Qualifiziertes Personal
The associated device/system may only be set up and operated using this documentation. The device/system
must only be commissioned and operated by qualified personnel. Qualified persons are defined as persons who
are authorized to commission, to ground, and to tag circuits, equipment, and systems in accordance with
established safety practices and standards.
Proper use
Please note the following:
Alarm
The equipment may only be used for single purpose applications explicitly described in the catalog and in the
technical description and it may only be used along with third-party devices and components recommended by
Siemens. This product can only function correctly and safely if it is transported, stored, set up, and installed
correctly, and operated and maintained as recommended.
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.
Copyright Siemens AG 12/2007. All rights reserved.
The reproduction, transmission or use of this document or its contents is not permitted
without express written authority. Offenders will be liable for damages. All rights, including
rights created by patent grant or registration or a utility model or design, are reserved.
Liability disclaimer
We have checked that the contents of this document correspond to the hardware and
software described. Nonetheless, differences might exist and therefore we cannot
guarantee that they are completely identical. The information given in this publication is
reviewed at regular intervals and any corrections that might be necessary are made in the
subsequent editions.
Siemens AG
Automation and Drives
Industrial Automations
4848, 90327 Nuremberg
Germany
Siemens AG 2007
Technical data subject to change without prior notice
Siemens AG Order No.: 6SL3097-2AM00-0BP4

Chassis Power Units Liquid Cooled
SINAMICS S120 Equipment Manual, Edition 12/2007, 6SL3097-2AM00-0BP4 I
Foreword
Information on the SINAMICS S documentation
The SINAMICS S documentation is divided into the following areas:
•General Documentation / Catalogs
•Manufacturer/service documentation
•Electronic documentation
This documentation is an integral part of the manufacturer/service documentation developed
for SINAMICS. All documents can be obtained separately.
You can obtain detailed information about the documents named in the documentation
overview and other documents available for SINAMICS from your local Siemens office.
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.
The contents of this documentation are not part of an earlier or existing agreement, a
promise, or a legal agreement, nor do they change this. All obligations entered into by
Siemens result from the respective contract of sale that contains the complete and sole valid
warranty arrangements. These contractual warranty provisions are neither extended nor
curbed as a result of the statements made in this documentation.
Audience
This documentation is aimed at machine and plant builders, commissioning engineers, and
service personnel who use SINAMICS.
Objective
This manual describes the hardware components of the SINAMICS S system. It provides
information about installation, electrical connection, and cabinet design.

Foreword
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II SINAMICS S120 Equipment Manual, Edition 12/2007, 6SL3097-2AM00-0BP4
Technical support
If you have any questions, please get in touch with our Hotline:
European and African time zones
A&D Technical Support
Tel.: [phone] - 222
Fax: [phone] - 223
Internet: http://www.siemens.com/automation/support-request
E-mail: [email protected]
Asian and Australian time zones
A&D Technical Support
Tel.: [phone]
Fax: [phone]
Internet: http://www.siemens.com/automation/support-request
E-mail: [email protected]
American time zone
A&D Technical Support
Tel.: [phone]
Fax: [phone]
Internet: http://www.siemens.com/automation/support-request
E-mail: [email protected]
Note
Country telephone numbers for technical support are provided under the following Internet
address:
http://www.siemens.com/automation/service&support
Internet Address
Up-to-date information about our products can be found on the Internet at the following
address:
http://www.siemens.com/motioncontrol
You can find information on SINAMICS S120 at:
http://www.siemens.com/sinamics

Foreword
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SINAMICS S120 Equipment Manual, Edition 12/2007, 6SL3097-2AM00-0BP4 III
ESD notices
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 in ESD areas with conductive flooring may only handle electronic components
if:
•They are grounded with an ESD wrist band
•They are wearing ESD shoes or ESD shoe 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 must only be taken on boards when the measuring instrument 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 housing).

Foreword
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IV SINAMICS S120 Equipment Manual, Edition 12/2007, 6SL3097-2AM00-0BP4
Safety information
Danger
Commissioning shall not start until you have ensured that the machine in which the
components described here are to be installed complies with Directive 98/37/EC.
SINAMICS S equipment must only be commissioned by suitably qualified personnel.
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.
When electrical equipment and motors are operated, the electrical circuits automatically
conduct a dangerous voltage.
Dangerous mechanical movements may occur in the system during operation.
All work on the electrical system must be carried out when the system has been
disconnected from the power supply.
Warning
Safe, problem-free operation of SINAMICS S equipment assumes proper transportation,
storage, 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 plant-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
may be connected to any of the terminals on the electronic modules.
Note
When operated in dry operating areas, SINAMICS equipment with AC motors conforms to
Low-Voltage Directive 73/23/EEC.
SINAMICS S devices fulfill EMC Directive 89/336/EEC or 2004/108/EEC in the configuration
specified in the associated EC Declaration of Conformity and when the EMC installation
guideline is implemented, Order No. 6FC5297-AD30-0AP.
Caution
Operating the equipment in the immediate vicinity (< 1.5 m) of mobile telephones with a
transmitter power of > 1 W may lead to incorrect operation.

Foreword
Chassis Power Units Liquid Cooled
SINAMICS S120 Equipment Manual, Edition 12/2007, 6SL3097-2AM00-0BP4 V
Residual risks of power drive systems
When carrying out a risk assessment of the machine/plant in accordance with the EU
Machinery Directive, the machine manufacturer/plant operator 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
–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
–Improper protective conductor connection at high leakage currents.
4. Electrical, magnetic, and electromagnetic fields that can pose a risk to people with a
pacemaker and/or implants if they are too close.
5. Emission of pollutants if components or packaging are not disposed of properly.
An assessment of the residual risks of Power Drive System components (see points 1 to 5
above, but excluding point 4) established that these risks do not exceed the specified limit
values.
For more information about residual risks of the Power Drive System components, see the
relevant chapters in the technical user documentation.

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VI SINAMICS S120 Equipment Manual, Edition 12/2007, 6SL3097-2AM00-0BP4
Warning
Electromagnetic fields "electro smog"
Electromagnetic fields are generated by the operation of electrical power engineering
installations such as transformers, converters or motors.
Electromagnetic fields can interfere with electronic devices, which could cause them to
malfunction. For example, the operation of heart pacemakers can be impaired, potentially
leading to damage to a person's health or even death. It is therefore forbidden for persons
with heart pacemakers to enter these areas.
The plant operator is responsible for taking appropriate measures (labels and hazard
warnings) to adequately protect operating personnel and others against any possible risk.
•Observe the relevant nationally applicable health and safety regulations. In Germany,
"electromagnetic fields" are subject to regulations BGV B11 and BGR B11 stipulated by
the German statutory industrial accident insurance institution.
•Display adequate hazard warning notices.
•Place barriers around hazardous areas.
•Take measures, e.g. using shields, to reduce electromagnetic fields at their source.
•Make sure that personnel are wearing the appropriate protective gear.

Table of contents
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SINAMICS S120 Equipment Manual, Edition 12/2007, 6SL3097-2AM00-0BP4 VII
Table of contents
1System Overview.................................................................................................................................... 1-1
1.1 The SINAMICS range of drives .................................................................................................... 1-1
1.2 SINAMICS S120 drive system...................................................................................................... 1-3
1.3 Technical specifications................................................................................................................ 1-7
1.4 Structure of a drive system with SINAMICS S120 chassis liquid cooled ..................................... 1-9
1.4.1 Structure of a drive system with SINAMICS S120 and Power Module ........................................ 1-9
1.4.2 Structure of a drive system with SINAMICS S120 and regulated infeed ................................... 1-10
1.4.3 Structure of a drive system with SINAMICS S120 and unregulated infeed ............................... 1-11
2Line-Side Power Components ................................................................................................................ 2-1
2.1 Line reactors for Power Modules.................................................................................................. 2-1
2.1.1 Description.................................................................................................................................... 2-1
2.1.2 Safety information......................................................................................................................... 2-1
2.1.3 Dimension drawing ....................................................................................................................... 2-2
2.1.4 Technical specifications................................................................................................................ 2-3
2.2 Line reactors for Basic Line Modules ...........................................................................................2-4
2.2.1 Description.................................................................................................................................... 2-4
2.2.2 Safety information......................................................................................................................... 2-4
2.2.3 Dimension drawing ....................................................................................................................... 2-5
2.2.4 Technical specifications................................................................................................................ 2-7
2.3 Active Interface Modules .............................................................................................................. 2-8
2.3.1 Description.................................................................................................................................... 2-8
2.3.2 Safety instructions ........................................................................................................................ 2-9
2.3.3 Interface description ................................................................................................................... 2-10
2.3.3.1 Overview..................................................................................................................................... 2-10
2.3.3.2 Sample connection ..................................................................................................................... 2-13
2.3.3.3 X1, X2 Line / Load Connection................................................................................................... 2-14
2.3.3.4 DRIVE-CLiQ interface X500....................................................................................................... 2-15
2.3.3.5 Terminal Block X609 .................................................................................................................. 2-15
2.3.3.6 Meaning of the LED on the Voltage Sensing Module (VSM) in the Active Interface Module .... 2-16
2.3.4 Dimension Drawing .................................................................................................................... 2-17
2.3.5 Electrical connection................................................................................................................... 2-20
2.3.6 Technical specifications.............................................................................................................. 2-21
2.3.6.1 Derating factors .......................................................................................................................... 2-23
3Power Modules....................................................................................................................................... 3-1
3.1 Description.................................................................................................................................... 3-1
3.2 Safety information......................................................................................................................... 3-3
3.3 Interface description ..................................................................................................................... 3-4
3.3.1 Overview....................................................................................................................................... 3-4
3.3.2 Connection example..................................................................................................................... 3-6
3.3.3 Line/DC link/motor connection...................................................................................................... 3-7
3.3.4 Terminal block X9......................................................................................................................... 3-7
3.3.5 Terminal block X41....................................................................................................................... 3-8
3.3.6 Terminal block X42....................................................................................................................... 3-8
3.3.7 DRIVE-CLiQ interfaces X400-X402 ............................................................................................. 3-8
3.3.8 Cooling circuit connections........................................................................................................... 3-9
3.3.9 Meaning of the LEDs on the Control Interface Board in the Power Module ................................ 3-9

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VIII SINAMICS S120 Equipment Manual, Edition 12/2007, 6SL3097-2AM00-0BP4
3.4 Dimension drawing ..................................................................................................................... 3-10
3.5 Installation................................................................................................................................... 3-12
3.6 Electrical connection................................................................................................................... 3-13
3.7 Technical specifications.............................................................................................................. 3-14
3.7.1 Overload capability ..................................................................................................................... 3-15
3.7.2 Derating factors .......................................................................................................................... 3-16
3.7.2.1 Derating factors as a function of coolant temperature................................................................ 3-16
3.7.2.2 Derating factors as a function of ambient temperature .............................................................. 3-17
3.7.2.3 Derating factors as a function of installation altitude .................................................................. 3-17
3.7.2.4 Current derating as a function of pulse frequency...................................................................... 3-18
4Line Modules .......................................................................................................................................... 4-1
4.1 Introduction ................................................................................................................................... 4-1
4.2 Basic Line Modules....................................................................................................................... 4-2
4.2.1 Description.................................................................................................................................... 4-2
4.2.2 Safety information......................................................................................................................... 4-4
4.2.3 Interface description ..................................................................................................................... 4-5
4.2.3.1 Overview....................................................................................................................................... 4-5
4.2.3.2 Connection example..................................................................................................................... 4-7
4.2.3.3 Line supply/load connection ......................................................................................................... 4-7
4.2.3.4 Terminal block X9 ......................................................................................................................... 4-8
4.2.3.5 Terminal block X41....................................................................................................................... 4-8
4.2.3.6 Terminal block X42....................................................................................................................... 4-8
4.2.3.7 DRIVE-CLiQ interfaces X400, X401, X402 .................................................................................. 4-9
4.2.3.8 Cooling circuit connections........................................................................................................... 4-9
4.2.3.9 Meaning of the LEDs on the Control Interface Board in the Basic Line Module ........................ 4-10
4.2.4 Dimension drawing ..................................................................................................................... 4-11
4.2.5 Installation................................................................................................................................... 4-13
4.2.6 Electrical connection................................................................................................................... 4-14
4.2.7 Technical specifications.............................................................................................................. 4-15
4.2.7.1 Derating factors .......................................................................................................................... 4-17
4.3 Active Line Modules.................................................................................................................... 4-19
4.3.1 Description.................................................................................................................................. 4-19
4.3.2 Safety instructions ...................................................................................................................... 4-21
4.3.3 Interface description ................................................................................................................... 4-22
4.3.3.1 Overview..................................................................................................................................... 4-22
4.3.3.2 Sample connection ..................................................................................................................... 4-25
4.3.3.3 Line / load connection................................................................................................................. 4-25
4.3.3.4 Terminal block X9 ....................................................................................................................... 4-26
4.3.3.5 Terminal block X41..................................................................................................................... 4-26
4.3.3.6 Terminal block X42..................................................................................................................... 4-26
4.3.3.7 DRIVE-CLiQ interface X400-X402 ............................................................................................. 4-27
4.3.3.8 Cooling circuit connections......................................................................................................... 4-27
4.3.3.9 Meaning of the LEDs on the Control Interface Board in the Active Line Module ....................... 4-28
4.3.4 Dimension Drawing..................................................................................................................... 4-29
4.3.5 Installation................................................................................................................................... 4-32
4.3.6 Technical specifications.............................................................................................................. 4-33
4.3.6.1 Derating factors .......................................................................................................................... 4-35
5Motor Modules........................................................................................................................................ 5-1
5.1 Description.................................................................................................................................... 5-1
5.2 Safety information......................................................................................................................... 5-3
5.3 Interface description ..................................................................................................................... 5-4
5.3.1 Overview....................................................................................................................................... 5-4
5.3.2 Connection example..................................................................................................................... 5-8
5.3.3 DC link/motor connection.............................................................................................................. 5-8
5.3.4 Terminal block X9 ......................................................................................................................... 5-9
5.3.5 Terminal block X41....................................................................................................................... 5-9

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5.3.6 Terminal block X42....................................................................................................................... 5-9
5.3.7 DRIVE-CLiQ interface X400-X402 ............................................................................................. 5-10
5.3.8 Cooling circuit connections......................................................................................................... 5-10
5.3.9 Meaning of the LEDs on the Control Interface Board in the Motor Module ............................... 5-11
5.4 Dimension drawing ..................................................................................................................... 5-12
5.5 Installation................................................................................................................................... 5-16
5.6 Technical specifications.............................................................................................................. 5-17
5.6.1 Overload capability ..................................................................................................................... 5-21
5.6.2 Derating factors .......................................................................................................................... 5-22
5.6.2.1 Derating factors as a function of coolant temperature ............................................................... 5-22
5.6.2.2 Derating factors as a function of ambient temperature .............................................................. 5-23
5.6.2.3 Derating factors as a function of installation altitude.................................................................. 5-23
5.6.2.4 Current derating as a function of pulse frequency...................................................................... 5-24
5.6.3 Parallel switching of Motor Modules........................................................................................... 5-26
6Motor-Side Power Components.............................................................................................................. 6-1
6.1 Sinusoidal Filter ............................................................................................................................ 6-1
6.1.1 Description.................................................................................................................................... 6-1
6.1.2 Safety Information ........................................................................................................................ 6-2
6.1.3 Dimension Drawing ...................................................................................................................... 6-3
6.1.4 Technical Specifications ............................................................................................................... 6-4
6.2 Motor reactors............................................................................................................................... 6-5
6.2.1 Description.................................................................................................................................... 6-5
6.2.2 Safety information......................................................................................................................... 6-5
6.2.3 Dimension drawing ....................................................................................................................... 6-6
6.2.4 Technical specifications................................................................................................................ 6-9
6.3 dv/dt filter with Voltage Peak Limiter .......................................................................................... 6-11
6.3.1 Description.................................................................................................................................. 6-11
6.3.2 Safety information....................................................................................................................... 6-13
6.3.3 Interface description ................................................................................................................... 6-14
6.3.4 Connecting the dv/dt filter with Voltage Peak Limiter................................................................. 6-16
6.3.5 Dimension drawing of dv/dt reactor............................................................................................ 6-18
6.3.6 Dimension drawing of voltage limiting network .......................................................................... 6-21
6.3.7 Technical specifications.............................................................................................................. 6-24
7Cabinet Design and EMC ....................................................................................................................... 7-1
7.1 Information.................................................................................................................................... 7-1
7.1.1 General......................................................................................................................................... 7-1
7.1.2 Safety information......................................................................................................................... 7-2
7.1.3 Standards and guidelines............................................................................................................. 7-3
7.2 Basic information about EMC....................................................................................................... 7-4
7.2.1 Introduction to EMC...................................................................................................................... 7-4
7.2.2 Interference and noise immunity .................................................................................................. 7-4
7.3 EMC-compliant drive installation .................................................................................................. 7-6
7.3.1 General......................................................................................................................................... 7-6
7.3.2 EMC planning ............................................................................................................................... 7-6
7.3.3 The zone concept ......................................................................................................................... 7-8
7.3.4 Wiring and shielding ..................................................................................................................... 7-9
7.3.5 Design......................................................................................................................................... 7-11
7.4 Overview of devices required for operation................................................................................ 7-12
7.4.1 General....................................................................................................................................... 7-12
7.4.2 Line disconnection devices......................................................................................................... 7-12
7.4.3 Overcurrent protection by line fuse or circuit-breaker ................................................................ 7-12
7.4.4 Line contactor ............................................................................................................................. 7-12
7.5 Arrangement of components and equipment ............................................................................. 7-13
7.5.1 General....................................................................................................................................... 7-13
7.5.2 Drive line-up................................................................................................................................ 7-13
7.6 Horizontal installation ................................................................................................................. 7-14

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8Cooling circuit and coolant properties..................................................................................................... 8-1
8.1 Cooling circuits ............................................................................................................................. 8-1
8.1.1 Cooling circuit for aluminum heatsink........................................................................................... 8-3
8.1.2 Cooling circuits for stainless steel heatsinks ................................................................................ 8-5
8.1.3 Prevention of cavitation ................................................................................................................ 8-6
8.1.4 Cooling circuit configuring information.......................................................................................... 8-7
8.1.5 Equipotential bonding ................................................................................................................. 8-12
8.2 Coolant definition........................................................................................................................ 8-13
8.2.1 Inhibitors, anti-freeze, biocides................................................................................................... 8-14
8.3 Materials ..................................................................................................................................... 8-16
8.4 Condensation protection............................................................................................................. 8-17
8.5 Degrees of protection ................................................................................................................. 8-17
8.6 Connection system ..................................................................................................................... 8-19
8.7 Commissioning, service.............................................................................................................. 8-19
9Maintenance and servicing ..................................................................................................................... 9-1
9.1 Chapter content ............................................................................................................................ 9-1
9.2 Maintenance ................................................................................................................................. 9-2
9.2.1 Cleaning........................................................................................................................................ 9-2
9.3 Servicing ....................................................................................................................................... 9-3
9.4 Replacing components ................................................................................................................. 9-4
9.4.1 Replacing the Control Interface Board, Power Module, frame size FL ........................................ 9-5
9.4.2 Replacing the Control Interface Board, Power Module, frame size GL........................................ 9-7
9.4.3 Replacing the Control Interface Board, Motor Module, frame size FXL....................................... 9-9
9.4.4 Replacing the Control Interface Board, Active Line Module and Motor Module, frame size GXL.... 9-11
9.4.5 Replacing the Control Interface Board, Active Line Module and Motor Module, frame size HXL .... 9-13
9.4.6 Replacing the Control Interface Board, Active Line Module and Motor Module, frame size JXL ..... 9-15
9.4.7 Replacing the Control Interface Board, Basic Line Module, frame size FBL ............................. 9-17
9.4.8 Replacing the Control Interface Board, Basic Line Module, frame size GBL............................. 9-19
9.4.9 Replacing the fan, Power Module, frame size FL....................................................................... 9-21
9.4.10 Replacing the fan, Power Module, frame size GL...................................................................... 9-23
9.4.11 Replacing the fan, Motor Module, frame size FXL ..................................................................... 9-25
9.4.12 Replacing the fan, Active Line Module and Motor Module, frame size GXL.............................. 9-27
9.4.13 Replacing the fan, Active Line Module and Motor Module, frame size HXL .............................. 9-29
9.4.14 Replacing the fan, Active Line Module and Motor Module, frame size JXL............................... 9-31
9.4.15 Replacing the fan, Basic Line Module, frame size FBL.............................................................. 9-33
9.4.16 Replacing the fan, Basic Line Module, frame size GBL ............................................................. 9-35
9.4.17 Replacing the fan, Active Interface Module, frame size GI ........................................................ 9-37
9.4.18 Replacing the fan, Active Interface Module, frame size HI......................................................... 9-39
9.4.19 Replacing the fan, Active Interface Module, frame size JI ......................................................... 9-41
9.4.20 Replacing the Power Supply Board, Power Module, frame size FL........................................... 9-43
9.4.21 Replacing the Power Supply Board, Power Module, frame size GL .......................................... 9-45
9.4.22 Replacing the Power Supply Board, Motor Module, frame size FXL ......................................... 9-47
9.4.23 Replacing the Power Supply Board, Active Line Module and Motor Module, frame size GXL.. 9-49
9.4.24 Replacing the Power Supply Board, Active Line Module and Motor Module, frame size HXL .. 9-51
9.4.25 Replacing the Power Supply Board, Active Line Module and Motor Module, frame size JXL... 9-53
9.4.26 Replacing the Power Supply Board, Basic Line Module, frame size FBL.................................. 9-55
9.4.27 Replacing the Power Supply Board, Basic Line Module, frame size GBL ................................. 9-57
9.5 Reforming the DC link capacitors ...............................................................................................9-59
10 List of Abbreviations ............................................................................................................................. 10-1
10.1 List of Abbreviations ................................................................................................................... 10-1

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SINAMICS S120 Equipment Manual, Edition 12/2007, 6SL3097-2AM00-0BP4 1-1
System Overview 1
1.1 The SINAMICS range of drives
Application
SINAMICS is the new range of converters from Siemens designed for industrial mechanical
and plant engineering applications. SINAMICS offers solutions for all drive tasks:
•Simple pump and fan applications in the process industry.
•Complex individual drives in centrifuges, presses, extruders, elevators, as well as
conveyor and transport systems.
•Drive line-ups in textile, plastic film, and paper machines, as well as in rolling mill plants.
•Highly dynamic servo drives for machine tools, as well as packaging and printing
machines.
Fig. 1-1 SINAMICS applications

System Overview
1.1 The SINAMICS range of drives
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1-2 SINAMICS S120 Equipment Manual, Edition 12/2007, 6SL3097-2AM00-0BP4
Product variants
Depending on the application, the SINAMICS range offers the ideal version for any drive
task.
•SINAMICS G is designed for standard applications with induction motors. These
applications have less stringent requirements regarding the dynamics and accuracy of
the motor speed.
•SINAMICS S handles complex drive tasks with synchronous/induction motors and fulfills
stringent requirements regarding
–Dynamics and accuracy,
–Integration of extensive technological functions in the drive control system
Platform concept and Totally Integrated Automation
All SINAMICS versions are based on a platform concept. Joint hardware and software
components, as well as standardized tools for design, configuration, and commissioning
tasks ensure high-level integration across all components. SINAMICS handles a wide variety
of drive tasks with no system gaps. The different SINAMICS versions can be easily
combined with each other.
SINAMICS is part of the Siemens "Totally Integrated Automation" concept. Integrated
SINAMICS systems covering configuration, data storage, and communication at automation
level ensure low-maintenance solutions with the SIMATIC, SIMOTION, and SINUMERIK
control systems.
Fig. 1-2 SINAMICS as part of the Siemens modular automation concept

System Overview
1.2 SINAMICS S120 drive system
Chassis Power Units Liquid Cooled
SINAMICS S120 Equipment Manual, Edition 12/2007, 6SL3097-2AM00-0BP4 1-3
Quality to DIN EN ISO 9001
SINAMICS is able to meet the highest requirements in terms of quality. Comprehensive
quality assurance measures in all development and production processes ensure a
consistently high level of quality.
Of course, our quality assurance system is certified by an independent authority to
DIN EN ISO 9001.
Universal applications
SINAMICS meets the requirements of relevant international standards and regulations - from
the EN European standards through IEC to UL and cULus.
Note
A list of certified components is available on request from your local Siemens office.
1.2 SINAMICS S120 drive system
Modular system for sophisticated drive tasks
SINAMICS S120 solves complex drive tasks for a wide range of industrial applications and
is, therefore, designed as a modular system. Users can choose from many different
harmonized components and functions to create a solution that best meets their
requirements. SIZER, a high-performance engineering tool, makes it easier to choose and
determine the optimum drive configuration. SINAMICS S120 is supplemented by a wide
range of motors. Whether synchronous or asynchronous, all motor types are supported by
SINAMICS S120.
Particularly suitable for multi-axis applications
Coordinated drives that carry out drive tasks together are used in many mechanical and
plant engineering applications, including running gears in gantry cranes, stretching systems
in the textile industry, or paper machines and rolling mills. These require drives with a
connected DC link, which allows cost-saving energy balancing between braking and driving
axes.
SINAMICS S120 features Power Modules (AC-AC converters), Line Modules (infeed
modules) and Motor Modules (inverter modules) covering a wide power range which, having
been designed for seamless integration, pave the way for compact multi-axis drive
configurations.

System Overview
1.2 SINAMICS S120 drive system
Chassis Power Units Liquid Cooled
1-4 SINAMICS S120 Equipment Manual, Edition 12/2007, 6SL3097-2AM00-0BP4
Terminal
Module
1
45
3
1
2
3
4
5
Control Unit
Active Interface Module
Active Line Module
Single Motor Module
Double Motor Module
Sensor Module
PROCESS FIELD
2
13444
6
6
6
PC tools
SIZER and
STARTER
SITOP Type Booksize Type Chassis
Incoming
power
Line reactor
Line filter
Incoming
power
Power/signal line
DRIVE-CLiQ line
G_D21 1_EN_00017
Motors
without
encoder
Motors with
integrated
DRIVE-CLiQ
interface
Motors with
standard
encoder
SITOP
24 V DC
24 V DC
Motors with
integrated
DRIVE-CLiQ
interface
Motors with
standard
encoder
Motors
without
encoder
Option
Boards
Terminal
Modules
Option
Boards
Fig. 1-3 Overview of the SINAMICS S120 system
New system architecture with a central Control Unit
Electronically coordinated individual drives work together to perform your drive tasks. Higher-
level controllers operate the drives to achieve the required coordinated movement. This
requires cyclic data exchange between the control and all the drives. This exchange always
had to take place via a field bus, which required a great deal of time and effort for installation
and configuration. SINAMICS S120 takes a different approach. A central Control Unit
controls the drive for all connected axes and also establishes the technological links between
the drives and/or axes. Since all the required data is stored in the central Control Unit, it
does not need to be transferred. Inter-axis connections can be established within a Control
Unit and easily configured in the STARTER commissioning tool using a mouse.
Simple technological tasks can be carried out by the SINAMICS S120 Control Unit itself. For
complex numerical or motion-control tasks, high-performance SIMOTION D modules are
used instead.

System Overview
1.2 SINAMICS S120 drive system
Chassis Power Units Liquid Cooled
SINAMICS S120 Equipment Manual, Edition 12/2007, 6SL3097-2AM00-0BP4 1-5
DRIVE-CLiQ – a digital interface between all components
All SINAMICS S120 components, including the motors and encoders, are interconnected via
a joint serial interface called DRIVE-CLiQ. The standardized cables and connectors reduce
the variety of different parts and cut storage costs.
Converter boards (sensor modules) for converting standard encoder signals to DRIVE-CLiQ
are available for third-party motors or retrofit applications.
Electronic type plates in all components
All SINAMICS S120 components with a DRIVE-CLiQ interface have an electronic rating
plate This electronic type plate contains all the relevant technical data about that particular
component. In the motors, for example, this data includes the parameters of the electric
equivalent circuit diagram and characteristic values for the built-in motor encoder. The
Control Unit records this data automatically via DRIVE-CLiQ so that it does not need to be
entered during commissioning or when the equipment is replaced.
In addition to the technical data, the type plate includes logistical data (manufacturer ID,
order number, and globally unique ID). Since this data can be called up electronically on site
or remotely, all the components used in a machine can always be individually identified,
which helps simplify servicing.
SINAMICS S120 components
The SINAMICS S120 components are primarily used for multi-axis drive tasks.
The following power components are available:
•Line-side power components, such as fuses, contactors, line reactors and line filters for
switching the power supply and complying with EMC regulations.
•Power Modules which function as both a power infeed and an inverter.
•Line Modules, which supply power centrally to the DC link.
•DC link components (optional), which stabilize the DC link voltage.
•Motor Modules, which act as inverters, receive power from the DC link, and supply the
connected motors.
•Motor-side power components, such as motor reactors and dv/dt filters for reducing the
voltage loads on the motor windings.
To carry out the required functions, SINAMICS S120 is equipped with:
•A Control Unit that carries out all drive and technological functions across all axes.
•Supplementary system components that enhance functionality and offer different
interfaces for encoders and process signals.
The SINAMICS S120 components were developed for installation in cabinets. They have the
following features and characteristics:
•Easy to handle, simple installation and wiring
•Practical connection system, cable routing in accordance with EMC requirements
•Standardized design, seamless integration.

System Overview
1.2 SINAMICS S120 drive system
Chassis Power Units Liquid Cooled
1-6 SINAMICS S120 Equipment Manual, Edition 12/2007, 6SL3097-2AM00-0BP4
Boundary conditions for use
The Power Modules, Line Modules and Motor Modules are designed for connection to a
liquid coolant circuit which must be provided by the customer.
The design of this liquid coolant circuit is an important factor in determining the operational
reliability and service life of the equipment and the entire installation.
The main criteria are described in the following chapters.
Advantages of liquid cooling over air cooling
Liquid cooling systems are considerably more efficient at dissipating heat losses than air
cooling systems. As a result, liquid-cooled devices are much more compact than air-cooled
units with the same output rating. Since the heat losses generated by the electronic
components are almost completely dissipated by the liquid coolant, only very small cooling
fans are required. This makes the devices extremely quiet in operation. Due to their compact
dimensions and almost negligible cooling air requirement, liquid-cooled units are the
preferred solution wherever installation space is restricted and/or the ambient operating
conditions are rough. Control cabinets with liquid cooling are easy to implement as
hermetically sealed units with degrees of protection of IP54 or above.