Siemens SINAMICS S120 User manual

SINAMICS
Manual · 07/2012
SINAMICS S120 Combi
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SINAMICS
S120
SINAMICS S120 Combi
Manual
Edition 07/2012
6SL3097-4AV00-0BP3
Preface
System overview
1
Line-side power components
2
S120 Combi Power Modules
3
Reinforcement plates
4
External fan unit
5
Topology rules for DRIVE-
CLiQ
6
Motor Modules Booksize
Compact as expansion axes
7
DC link components
8
Electrically connecting Motor
Modules and DC link
components
9
Additional system
components
10
Encoder system connection
11
Accessories
12
Cabinet design and EMC
13
Service and maintenance
14
Appendix
A

Legal information
Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.
CAUTION
without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.
NOTICE
indicates that an unintended result or situation can occur if the relevant information is not taken into account.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
Qualified Personnel
The product/system described in this documentation may be operated only by personnel qualified for the specific
task in accordance with the relevant documentation, in particular its warning notices and safety instructions.
Qualified personnel are those who, based on their training and experience, are capable of identifying risks and
avoiding potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended
or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be complied with. The information in the relevant documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of Siemens AG. The remaining trademarks in this publication
may be trademarks whose use by third parties for their own purposes could violate the rights of the owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.
Siemens AG
Industry Sector
Postfach 48 48
90026 NÜRNBERG
GERMANY
Order number: 6SL3097-4AV00-0BP3
Ⓟ 07/2012 Technical data subject to change
Copyright © Siemens AG 2009,
2012.
All rights reserved

SINAMICS S120 Combi
Manual, Edition 07/2012, 6SL3097-4AV00-0BP3 3
Preface
Foreword
SINAMICS documentation
The SINAMICS documentation is organized in the following categories:
● General documentation / Catalogs
● User documentation
● Manufacturer / Service documentation
More information
Using the following link, you can find information on the topics:
● Ordering documentation/overview of documentation
● Additional links to download documents
● Using documentation online (find and search in manuals/information)
http://www.siemens.com/motioncontrol/docu
Please send any questions about the technical documentation (e.g. suggestions for
improvement, corrections) to the following e-mail address:
[e-mail]
My Documentation Manager
Using the following link, you can find information on how to create your own individual
documentation based on Siemens' content, and adapt it for your own machine
documentation:
http://www.siemens.com/mdm
Training
Using the following link, you can find information on SITRAIN - training from Siemens for
products, systems and automation engineering solutions:
http://www.siemens.com/sitrain
FAQs
You can find Frequently Asked Questions in the Service&Support pages under Product
Support.
http://support.automation.siemens.com

Preface
SINAMICS S120 Combi
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SINAMICS
You can find information on SINAMICS at:
http://www.siemens.com/sinamics.
Usage phases and the available tools/documents
Table 1 Usage phase and the available tools/documents
Usage phase Tools
Orientation SINAMICS S Sales Documentation
Planning/configuration SIZER configuration tool
Decision making/ordering SINAMICS S Catalogs
Configuring/installation •SINAMICS S120 Manuals
•SINAMICS S120 Combi Manual
•SINUMERIK 828D PPU Manual
Commissioning •SINAMICS S120 Combi List Manual
•SINUMERIK 828D Turning and Milling Commissioning Manual
Usage/operation •SINAMICS S120 Function Manual FH1
•SINAMICS S120 Combi List Manual
Maintenance/Service •SINAMICS S120 Combi Manual
•SINAMICS S120 Combi List Manual
Target group
This documentation is intended for machine manufacturers, commissioning engineers, and
service personnel who use the SINAMICS drive system.
Benefits
This manual provides information on the components and functions of devices so that the
target group is capable of installing, setting up, testing, operating, and troubleshooting the
devices safely and correctly.
Standard scope
The scope of the functionality described in this document can differ from the scope of the
functionality of the drive system that is actually supplied.
It may be possible for other functions not described in this documentation to be executed in
the drive system. This does not, however, represent an obligation to supply such functions
with a new control or when servicing.
Functions that are not available in a particular product version of the drive system may be
described in the documentation. The functionality of the supplied drive system should only
be taken from the ordering documentation.

Preface
SINAMICS S120 Combi
Manual, Edition 07/2012, 6SL3097-4AV00-0BP3 5
Extensions or changes made by the machine manufacturer must be documented by the
machine manufacturer.
For reasons of clarity, this documentation does not contain all of the detailed information on
all of the product types. This documentation cannot take into consideration every
conceivable type of installation, operation and service/maintenance.
Technical support
Country-specific telephone numbers for technical support are provided in the Internet under
Contact:
http://www.siemens.com/automation/service&support
EC Declarations of Conformity
The EC Declaration of Conformity for the EMC Directive can be found on the Internet at:
http://support.automation.siemens.com
There – as a search term – enter the number 15257461 or contact your local Siemens office.
The EC Declaration of Conformity for the Low Voltage Directive can be found on the Internet
at:
http://support.automation.siemens.com
There – as a search term – enter the number 22383669 .
Note
When operated in dry areas, SINAMICS S devices conform to the Low Voltage Directive
73/23/EEC or 2006/95/EEC.
Note
SINAMICS S devices fulfill EMC Directive 89/336/EEC or 2004/108/EEC in the configuration
specified in the associated EC Declaration of Conformity for EMC and when the
Configuration Manual EMC Installation Guideline, order number 6FC5297-0AD30-0P, is
implemented.
Note
The Manual describes a desired state which, if maintained, ensures the required level of
operational reliability and compliance with EMC limit values.
Should there be a deviation from the Equipment Manual requirements, appropriate actions
(e.g. measurements) must be taken to check/prove that the desired reliable operation is
ensured and EMC limit values are complied with.

Preface
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EMC limit values in South Korea
The EMC limit values to be complied with for South Korea correspond to the limit values of
the EMC product standard for variable-speed electric drives EN 61800-3, Category C2 or
limit value class A, Group 1 according to EN55011. By applying suitable supplementary
measures, the limit values according to Category C2 or according to limit value class A,
Group 1 are maintained. Further, additional measures may be required, for instance, using
an additional radio interference suppression filter (EMC filter). The measures for EMC-
compliant design of the system are described in detail in this manual respectively in the
Installation Guideline EMC.
The measures for EMC-compliant design of the system are described in detail in this manual
respectively in the Installation Guideline EMC.
Please note that the final statement on compliance with the standard is given by the
respective label attached to the individual unit.
Spare parts
Spare parts are available on the Internet at:
http://support.automation.siemens.com/WW/view/de/16612315
Test certificates
The Safety Integrated functions of SINAMICS components are generally certified by
independent institutes. An up-to-date list of certified components is available on request from
your local Siemens office. If you have any questions relating to certifications that have not
been completed, please ask your Siemens contact.

Preface
SINAMICS S120 Combi
Manual, Edition 07/2012, 6SL3097-4AV00-0BP3 7
ESD information
CAUTION
Electrostatic sensitive devices (ESDs) are individual components, integrated circuits, or
boards that may be damaged by either electrostatic fields or electrostatic discharge.
Regulations for handling ESD components:
When handling electronic components, you must ensure that the person carrying out the
work, the work place, and packaging are properly grounded.
Personnel may only come into contact with electronic components, if
•They are grounded with an ESD wrist band, or
•They are in ESD areas with conductive flooring, ESD shoes or ESD grounding straps.
Electronic boards should only be touched if absolutely necessary. They must only be
handled on the front panel or, in the case of printed circuit boards, at the edge.
Electronic boards must not come into contact with plastics or items of clothing containing
synthetic fibers.
Boards must only be placed on conductive surfaces (work surfaces with ESD surface,
conductive ESD foam, ESD packing bag, ESD transport container).
Do not place boards near display units, monitors, or television sets (minimum distance from
screen: 10 cm).
Measurements may only be taken on boards when the measuring device is grounded (via
protective conductors, for example) or the measuring probe is briefly discharged before
measurements are taken with an isolated measuring device (for example, touching a bare
metal housing).
DANGER
Electrical, magnetic and electromagnetic fields (EMF) that occur during operation can pose
a danger to persons who are present in the direct vicinity of the product - especially
persons with pacemakers, implants, or similar devices.
The relevant directives and standards must be observed by the machine/plant operators
and persons present in the vicinity of the product. These are, for example, EMF Directive
2004/40/EEC and standards EN 12198-1 to -3 applying to the European Economic Area
(EEA) and in Germany the accident prevention regulation BGV 11 and the associated rule
BGR 11 "Electromagnetic fields" from the German employer's liability accident insurance
association.
These state that a hazard analysis must be drawn up for every workplace, from which
measures for reducing dangers and their impact on persons are derived and applied, and
exposure and danger zones are defined and observed.
The relevant safety notes in each chapter must be observed.

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SINAMICS S120 Combi
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General safety instructions
DANGER
Commissioning is absolutely prohibited until it has been completely ensured that the
machine, in which the components described here are to be installed, is in full compliance
with the provisions of the EC Machinery Directive.
Only qualified personnel may install, commission and service SINAMICS S units.
The personnel must take into account the information provided in the technical customer
documentation for the product, and be familiar with and observe the specified danger and
warning notices.
Operational electrical equipment and motors have parts and components which are at
hazardous voltage levels that may cause serious injuries or death when touched.
All work on the electrical system must be carried out when the system has been
disconnected from the power supply.
In combination with the drive system, the motors are generally approved for operation on
TN and TT line supplies with grounded neutral and on IT line supplies.
In operation on IT line supplies, the occurrence of a first fault between an active part and
ground must be signaled by a monitoring device. In accordance with IEC 60364-4-41 it is
recommended that the first fault should be eliminated as quickly as practically possible.
For line supplies with a grounded phase conductor, an isolating transformer with grounded
neutral (secondary side) must be connected between the supply and the drive system to
protect the motor insulation from excessive stress. The majority of TT line supplies have a
grounded phase conductor, so in this case an isolating transformer must be used.
DANGER
Correct and safe operation of SINAMICS S units assumes correct transportation in the
transport packaging, correct long-term storage in the transport packaging, setup and
installation, as well as careful operation and maintenance.
The details in the catalogs and proposals also apply to the design of special equipment
versions.
In addition to the danger and warning information provided in the technical customer
documentation, the applicable national, local, and system-specific regulations and
requirements must be taken into account.
According to EN 61800-5-1 and UL 508 only safely isolated protective extra-low voltages of
the electronic modules may be connected to all connections and terminals.
DANGER
Using protection against direct contact via DVC A (PELV) is only permissible in areas with
equipotential bonding and in dry rooms indoors. If these conditions are not fulfilled, other
protective measures against electric shock (e.g. protection through protective impedances
or limited voltage, or use of protection class I and II) must be used.

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SINAMICS S120 Combi
Manual, Edition 07/2012, 6SL3097-4AV00-0BP3 9
DANGER
As part of routine tests, SINAMICS S components will undergo a voltage test in accordance
with EN 61800-5-1. Before the voltage test is performed on the electrical equipment of
machines to EN 60204-1, Section 18.4, all connections of SINAMICS units must be
disconnected/unplugged to prevent them from being damaged.
Motors should be connected up corresponding to the circuit diagram supplied with the
motor (refer to the connection examples of Motor Modules). They must not be connected
directly to the three-phase supply because this will damage them.
WARNING
Operating the equipment in the immediate vicinity (< 1.8 m) of cell phones with a
transmitter power of > 1 W may cause the equipment to malfunction.
Explanation of symbols
Table 2 Symbols
Symbol Meaning
Protective earth (PE)
Ground (e.g. M 24 V)
Functional ground
Equipotential bonding

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

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SINAMICS S120 Combi
Manual, Edition 07/2012, 6SL3097-4AV00-0BP3 11
4. Electrical, magnetic and electromagnetic fields generated in operation that can pose a
risk to people with a pacemaker, implants or metal replacement joints, etc. if they are too
close.
5. Release of environmental pollutants or emissions as a result of improper operation of the
system and/or failure to dispose of components safely and correctly.
Note
Functional safety of SINAMICS components
The components must be protected against conductive contamination (e.g. by installing them
in a cabinet with degree of protection IP54B to EN 60529).
Assuming that conductive contamination at the installation site can definitely be excluded, a
lower degree of cabinet protection may be permitted.
For more information about residual risks of the components in a power drive system, see
the relevant chapters in the technical user documentation.

Preface
SINAMICS S120 Combi
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SINAMICS S120 Combi
Manual, Edition 07/2012, 6SL3097-4AV00-0BP3 13
Table of contents
Preface ...................................................................................................................................................... 3
1 System overview...................................................................................................................................... 21
1.1 SINAMICS S120 Combi components ..........................................................................................21
1.2 System data .................................................................................................................................23
1.3 Derating as a function of the installation altitude and ambient temperature................................25
1.4 Standards.....................................................................................................................................26
2 Line-side power components................................................................................................................... 29
2.1 Introduction ..................................................................................................................................29
2.2 Information on the disconnector unit............................................................................................30
2.3 Overcurrent protection by means of line fuses and circuit breakers............................................30
2.4 Line supply connection via residual-current devices ...................................................................33
2.5 Overvoltage protection.................................................................................................................34
2.6 Line filters.....................................................................................................................................35
2.6.1 Description ...................................................................................................................................35
2.6.2 Safety information ........................................................................................................................35
2.6.3 Interface description.....................................................................................................................37
2.6.3.1 Overview ......................................................................................................................................37
2.6.3.2 Line/load connection ....................................................................................................................38
2.6.4 Dimension drawing ......................................................................................................................38
2.6.5 Technical data..............................................................................................................................39
2.7 Line reactors ................................................................................................................................40
2.7.1 Description ...................................................................................................................................40
2.7.2 Safety information ........................................................................................................................40
2.7.3 Connection description ................................................................................................................41
2.7.3.1 Overview ......................................................................................................................................41
2.7.3.2 Line/load connection ....................................................................................................................41
2.7.4 Dimension drawings.....................................................................................................................42
2.7.5 Technical data..............................................................................................................................44
2.8 Line connection versions .............................................................................................................45
2.8.1 Ways of connecting the line supply .............................................................................................45
2.8.2 Operating line connection components on the line supply ..........................................................46
2.8.3 Operation of the line connection components via a transformer .................................................47
2.8.3.1 Safety information ........................................................................................................................47
2.8.3.2 Line connection conditions...........................................................................................................47
2.8.3.3 Dimensioning an isolating transformer/autotransformer for several loads ..................................48
2.8.3.4 Operating line connection components via an autotransformer ..................................................53
2.8.3.5 Operating line connection components via an isolating transformer...........................................54

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14 Manual, Edition 07/2012, 6SL3097-4AV00-0BP3
3 S120 Combi Power Modules ................................................................................................................... 57
3.1 Introduction ................................................................................................................................. 57
3.1.1 Description .................................................................................................................................. 57
3.1.2 Module versions .......................................................................................................................... 58
3.1.3 Approved controls ....................................................................................................................... 59
3.1.4 Expansion axes that can be connected ...................................................................................... 59
3.2 Safety information ....................................................................................................................... 60
3.3 Interface description.................................................................................................................... 63
3.3.1 Overview diagrams ..................................................................................................................... 63
3.3.2 X1 line connection....................................................................................................................... 68
3.3.3 X2-X5 motor connection.............................................................................................................. 69
3.3.4 X11 brake connection ................................................................................................................. 70
3.3.5 X12/X13 fan connection.............................................................................................................. 70
3.3.6 X21/X22 EP terminals................................................................................................................. 71
3.3.7 X200-X205 DRIVE-CLiQ interfaces ............................................................................................ 72
3.3.8 X220 TTL encoder ...................................................................................................................... 74
3.3.9 X224 24 V connector................................................................................................................... 78
3.4 Connection examples.................................................................................................................. 79
3.5 Meaning of the LEDs on the S120 Combi................................................................................... 82
3.6 Dimension drawings.................................................................................................................... 83
3.7 Installation ................................................................................................................................... 84
3.7.1 Drilling patterns and installation cut-outs .................................................................................... 84
3.7.2 Installing an S120 Combi Power Module....................................................................................86
3.8 Electrical connection ................................................................................................................... 87
3.8.1 Line supply cable ........................................................................................................................ 88
3.8.2 Power cables for motors ............................................................................................................. 89
3.8.3 Signal cables at the EP terminals ............................................................................................... 90
3.9 Technical data............................................................................................................................. 91
3.9.1 Characteristics ............................................................................................................................ 96
4 Reinforcement plates............................................................................................................................... 99
4.1 Description .................................................................................................................................. 99
4.2 Installation ................................................................................................................................. 100
4.3 Technical data........................................................................................................................... 102
5 External fan unit..................................................................................................................................... 103
5.1 Description ................................................................................................................................ 103
5.2 Overview ................................................................................................................................... 104
5.3 Dimension drawing.................................................................................................................... 105
5.4 Installation ................................................................................................................................. 106
5.5 Technical data........................................................................................................................... 109
6 Topology rules for DRIVE-CLiQ............................................................................................................. 111
6.1 Connection examples................................................................................................................ 113
6.1.1 Operation with a 3 axes Power Module .................................................................................... 113

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6.1.2 Operation with a 4 axes Power Module.....................................................................................115
7 Motor Modules Booksize Compact as expansion axes.......................................................................... 119
7.1 Description .................................................................................................................................119
7.2 Safety information ......................................................................................................................120
7.3 Interface description...................................................................................................................122
7.3.1 Overview ....................................................................................................................................122
7.3.2 X1/X2 motor connection.............................................................................................................124
7.3.3 X11/X12 motor brake connection ..............................................................................................124
7.3.4 X21/X22 EP terminals / temperature sensor Motor Module ......................................................125
7.3.5 X200-X203 DRIVE-CLiQ interface.............................................................................................126
7.4 Connection example ..................................................................................................................127
7.5 Meaning of the LEDs on the Motor Module Booksize Compact................................................128
7.6 Dimension drawings...................................................................................................................129
7.7 Installation..................................................................................................................................132
7.8 Technical data............................................................................................................................133
7.8.1 Characteristics ...........................................................................................................................135
8 DC link components............................................................................................................................... 139
8.1 Braking Module Booksize ..........................................................................................................139
8.1.1 Description .................................................................................................................................139
8.1.2 Safety information ......................................................................................................................140
8.1.3 Interface description...................................................................................................................141
8.1.3.1 Overview ....................................................................................................................................141
8.1.3.2 X1 braking resistor connection...................................................................................................142
8.1.3.3 X21 digital inputs/outputs...........................................................................................................143
8.1.4 Connection example ..................................................................................................................144
8.1.5 Meaning of LEDs .......................................................................................................................145
8.1.6 Dimension drawing ....................................................................................................................146
8.1.7 Installation..................................................................................................................................147
8.1.8 Technical data............................................................................................................................148
8.1.8.1 Characteristic curves .................................................................................................................148
8.1.8.2 Configuration instructions ..........................................................................................................149
8.2 Control Supply Module CSM......................................................................................................150
8.2.1 Description .................................................................................................................................150
8.2.2 Safety information ......................................................................................................................151
8.2.3 Interface description...................................................................................................................152
8.2.3.1 Overview ....................................................................................................................................152
8.2.3.2 X1 line connection......................................................................................................................153
8.2.3.3 X21 signaling contact.................................................................................................................153
8.2.3.4 X24 24 V terminal adapter .........................................................................................................154
8.2.3.5 S1 DIP switch.............................................................................................................................155
8.2.4 Connection example ..................................................................................................................156
8.2.5 Meaning of the LEDs on the Control Supply Module.................................................................158
8.2.6 Dimension drawing ....................................................................................................................159
8.2.7 Installation..................................................................................................................................160
8.2.8 Technical data............................................................................................................................161
8.3 Braking resistors ........................................................................................................................162

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8.3.1 Description ................................................................................................................................ 162
8.3.2 Safety information ..................................................................................................................... 162
8.3.3 Dimension drawings.................................................................................................................. 163
8.3.4 Technical data........................................................................................................................... 165
9 Electrically connecting Motor Modules and DC link components ........................................................... 167
9.1 Introduction ............................................................................................................................... 167
9.2 Removing the front cover and opening the DC link cover on the S120 Combi ........................ 167
9.3 Connection of DC link busbars and 24 V busbars .................................................................... 169
9.4 Connecting an additional component........................................................................................ 171
10 Additional system components .............................................................................................................. 173
10.1 Terminal Module TM54F........................................................................................................... 173
10.1.1 Description ................................................................................................................................ 173
10.1.2 Safety information ..................................................................................................................... 174
10.1.3 Interface description.................................................................................................................. 174
10.1.3.1 Overview ................................................................................................................................... 174
10.1.3.2 X500/X501 DRIVE-CLiQ interfaces .......................................................................................... 175
10.1.3.3 X514 power supply for digital outputs and sensors .................................................................. 175
10.1.3.4 X520 sensor power supply........................................................................................................ 176
10.1.3.5 X521 fail-safe digital inputs + power supply with forced dormant error detection .................... 176
10.1.3.6 X522 fail-safe digital inputs ....................................................................................................... 177
10.1.3.7 X523 fail-safe digital output....................................................................................................... 178
10.1.3.8 X524 Electronics power supply................................................................................................. 179
10.1.3.9 X525 fail-safe digital output....................................................................................................... 180
10.1.3.10 X531 fail-safe digital inputs + power supply with forced dormant error detection ............... 181
10.1.3.11 X532 fail-safe digital inputs .................................................................................................. 182
10.1.3.12 X533 fail-safe digital output.................................................................................................. 183
10.1.3.13 X535 fail-safe digital output.................................................................................................. 184
10.1.4 Connection example ................................................................................................................. 185
10.1.5 Meaning of LEDs....................................................................................................................... 186
10.1.6 Dimension drawing.................................................................................................................... 188
10.1.7 Installation ................................................................................................................................. 189
10.1.8 Protective conductor connection and shield support ................................................................ 190
10.1.9 Technical data........................................................................................................................... 191
10.2 DRIVE-CLiQ Hub Module DMC20 ............................................................................................ 192
10.2.1 Description ................................................................................................................................ 192
10.2.2 Safety information ..................................................................................................................... 192
10.2.3 Interface description.................................................................................................................. 193
10.2.3.1 Overview ................................................................................................................................... 193
10.2.3.2 X524 Electronics power supply................................................................................................. 194
10.2.3.3 X500 - X505 DRIVE-CLiQ interfaces........................................................................................ 194
10.2.3.4 Meaning of the LED on the DMC20.......................................................................................... 195
10.2.4 Dimension drawing.................................................................................................................... 196
10.2.5 Installation ................................................................................................................................. 196
10.2.6 Technical data........................................................................................................................... 197
10.3 DRIVE-CLiQ Hub Module External DME20.............................................................................. 198
10.3.1 Description ................................................................................................................................ 198
10.3.2 Safety information ..................................................................................................................... 198
10.3.3 Interface description.................................................................................................................. 199

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SINAMICS S120 Combi
Manual, Edition 07/2012, 6SL3097-4AV00-0BP3 17
10.3.3.1 Overview ....................................................................................................................................199
10.3.3.2 X500-X505 DRIVE-CLiQ interfaces...........................................................................................200
10.3.3.3 X524 electronics power supply ..................................................................................................201
10.3.4 Dimension drawing ....................................................................................................................202
10.3.5 Installation..................................................................................................................................203
10.3.6 Technical data............................................................................................................................203
10.3.7 Specifications for use with UL approval.....................................................................................204
11 Encoder system connection................................................................................................................... 205
11.1 Sensor Module Cabinet-Mounted SMC20 .................................................................................205
11.1.1 Description .................................................................................................................................205
11.1.2 Safety information ......................................................................................................................205
11.1.3 Interface description...................................................................................................................206
11.1.3.1 Overview ....................................................................................................................................206
11.1.3.2 X500 DRIVE-CLiQ interface ......................................................................................................207
11.1.3.3 X520 encoder system interface .................................................................................................208
11.1.3.4 X524 Electronics power supply..................................................................................................209
11.1.3.5 Meaning of LEDs on the Sensor Module Cabinet-Mounted SMC20 .........................................210
11.1.4 Dimension drawing ....................................................................................................................211
11.1.5 Installation..................................................................................................................................212
11.1.6 Technical data............................................................................................................................213
11.2 Sensor Module External SME20................................................................................................214
11.2.1 Description .................................................................................................................................214
11.2.2 Safety Information......................................................................................................................214
11.2.3 Interface description...................................................................................................................215
11.2.3.1 Overview ....................................................................................................................................215
11.2.3.2 Connection example ..................................................................................................................215
11.2.3.3 DRIVE-CLiQ interface................................................................................................................216
11.2.3.4 Encoder system interface ..........................................................................................................217
11.2.4 Dimension drawing ....................................................................................................................218
11.2.5 Installation..................................................................................................................................219
11.2.6 Technical data............................................................................................................................220
11.3 Sensor Module External SME25................................................................................................222
11.3.1 Description .................................................................................................................................222
11.3.2 Interface description...................................................................................................................222
11.3.2.1 Overview ....................................................................................................................................222
11.3.2.2 Connection example ..................................................................................................................223
11.3.2.3 DRIVE-CLiQ interface................................................................................................................223
11.3.2.4 Encoder system interface ..........................................................................................................224
11.3.3 Dimension drawing ....................................................................................................................225
11.3.4 Installation..................................................................................................................................225
11.3.5 Technical data............................................................................................................................226
12 Accessories ........................................................................................................................................... 229
12.1 DRIVE-CLiQ cabinet bushing ....................................................................................................229
12.1.1 Description .................................................................................................................................229
12.1.2 Safety Information......................................................................................................................229
12.1.3 Interface description...................................................................................................................230
12.1.3.1 Overview ....................................................................................................................................230
12.1.4 Dimension drawing ....................................................................................................................230
12.1.5 Mounting ....................................................................................................................................231

Table of contents
SINAMICS S120 Combi
18 Manual, Edition 07/2012, 6SL3097-4AV00-0BP3
12.1.6 Technical data........................................................................................................................... 232
12.2 DRIVE-CLiQ coupling ............................................................................................................... 233
12.2.1 Description ................................................................................................................................ 233
12.2.2 Safety information ..................................................................................................................... 233
12.2.3 Interface description.................................................................................................................. 233
12.2.3.1 Overview ................................................................................................................................... 233
12.2.4 Dimension drawing.................................................................................................................... 234
12.2.5 Mounting.................................................................................................................................... 234
12.2.6 Technical data........................................................................................................................... 235
13 Cabinet design and EMC....................................................................................................................... 237
13.1 General information................................................................................................................... 237
13.2 Safety information ..................................................................................................................... 238
13.3 Directives................................................................................................................................... 238
13.4 Notes on electromagnetic compatibility (EMC)......................................................................... 239
13.5 Cable shielding and routing....................................................................................................... 239
13.6 24 V DC supply ......................................................................................................................... 241
13.6.1 General information................................................................................................................... 241
13.6.2 24 V power supply and connection of components .................................................................. 242
13.6.3 Overcurrent protection in the 24 V solid-state circuit ................................................................ 244
13.6.4 Typical 24 V current consumption of the components.............................................................. 245
13.6.5 Selecting power supply units..................................................................................................... 247
13.7 Connection system.................................................................................................................... 248
13.7.1 DRIVE-CLiQ signal cables........................................................................................................ 248
13.7.2 Power cables for motors ........................................................................................................... 250
13.7.2.1 Approved power cables............................................................................................................. 250
13.7.3 Current-carrying capacity and derating factors for power cables and signal cables ................ 252
13.7.4 Connectable conductor cross-sections for spring-loaded terminals ......................................... 253
13.7.5 Connectable conductor cross-sections for screw terminals...................................................... 253
13.8 Protective connection and equipotential bonding ..................................................................... 255
13.9 Note on control cabinet cooling................................................................................................. 256
13.9.1 General information................................................................................................................... 256
13.9.2 Ventilation.................................................................................................................................. 259
13.9.3 Dimensioning Climate Control Equipment ................................................................................ 261
13.9.4 Power loss of components in rated operation........................................................................... 262
13.9.4.1 General information................................................................................................................... 262
13.9.4.2 Power losses for SINUMERIK 828D, DC link components and supplementary system
components............................................................................................................................... 262
13.9.4.3 Power losses for S120 Combi Power Modules......................................................................... 263
13.9.4.4 Power loss for line filters and line reactors ............................................................................... 263
13.9.4.5 Electronics losses of power units.............................................................................................. 264
13.9.4.6 Losses in partial-load operation ................................................................................................ 264
14 Service and maintenance ...................................................................................................................... 267
14.1 Technical Support ..................................................................................................................... 267
14.2 Spare parts................................................................................................................................ 268
14.3 Replacing the fan ...................................................................................................................... 269