With its separate power units and Control Units, the SINAMICS S120 drive system can be perfectly adapted to a wide variety of different drive tasks.

The Control Unit is selected according to the number of drives to be controlled and the required performance level, while the power unit must be rated to meet the energy requirements of the system. The connection between the Control Unit and power unit is made very simply using the digital system interface DRIVE?CLiQ.

Control Units

CU310?2 PN and SIMOTION D4x5?2 Control Units

CU310?2 DP and CU310?2 PN Control Units

CU310?2 Control Units are designed to control a single drive. They feature as standard a PROFIBUS interface (CU310?2 DP) or PROFINET interface (CU310?2 PN) and a TTL/HTL encoder evaluation circuit.

CU320?2 Control Unit

The CU320?2 Control Unit has been designed to control multiple drives. A CU320?2 Control Unit is capable of operating up to

• 6 drives in vector control mode.

The CU320?2 Control Unit can be used to control a group of single drives and implement basic drive technology functions.

SIMOTION D Control Units

SIMOCRANE Basic Technology uses the SIMOTION D435?2 Control Unit from the SIMOTION Motion Control System product range for the implementation of standard functions and the motion control of all main drives of a crane.

The STARTER commissioning tool is used to commission and diagnose the various Control Units. The SCOUT engineering software, which includes the STARTER tool, is required for SIMOTION D Control Units.

For further information about STARTER, see the section "Engineering software". For further information about the SIMOTION Motion Control System and SCOUT, see the section SIMOCRANE Basic Technology.

Power Modules

The simplest version of a SINAMICS S120 drive system consists of a CU310-2 Control Unit and a Power Module. A line rectifier, a voltage-source DC link and an inverter for supplying a motor are integrated in the Power Module.

Power Module in blocksize format with CU310?2 Control Unit

Power Modules are designed for single drives which are not capable of regenerating energy to the supply. Generated energy produced during braking is converted to heat via braking resistors.

Power Modules can also be operated by a CU320?2 Control Unit, SIMOTION D4x5?2 or CX32?2 Controller Extension, e.g. in configurations where a single drive has been added to a multi-axis drive group. In this case, the Power Modules in blocksize format must be equipped with the CUA31/CUA32 Control Unit Adapter. This is connected with the CU320?2 Control Unit, SIMOTION D4x5?2 or CX32?2 Controller Extension using DRIVE-CLiQ. Power Modules in chassis format can be directly connected to the Control Unit using a DRIVE-CLiQ cable.

Motor Modules

A voltage-source DC link and an inverter for supplying a motor are integrated in the Motor Module.

CU320?2 Control Unit, Line Module and three Motor Modules in booksize format

Motor Modules are designed for multi-axis drive systems and are controlled by a CU320?2 Control Unit, a SIMOTION D4x5?2 or CX32?2 Controller Extension. Motor Modules are interconnected by means of a shared DC busbar. Since the Motor Modules have a common DC link, they can exchange energy with one another, i.e. if one Motor Module operating in generator mode produces energy, the energy can be used by another Motor Module operating in motor mode. The voltage-source DC link is supplied with mains voltage by a Line Module.

Line Modules

Line Modules generate a DC voltage from the line voltage and supply Motor Modules with energy via the voltage-source DC link.

Basic Line Modules

Basic Line Modules are designed only for infeed operation, i.e. they are not capable of feeding regenerative energy back into the supply system. If regenerative energy is produced, e.g. when drives brake, it must be converted to heat by means of a Braking Module and a braking resistor. When a Basic Line Module is used as the infeed, the matching line reactor must be installed. A line filter can be installed optionally to restrict conducted interference to Class C2 limits (EN 61800?3).

Smart Line Modules

Smart Line Modules can supply energy and return regenerative energy to the supply system. Braking Modules and braking resistors are required only if the drives need to be decelerated in a controlled manner after a power failure – i.e. when energy cannot be regenerated into the line supply. When a Smart Line Module is used as the infeed, the matching line reactor must be installed. A line filter can be installed optionally to restrict conducted interference to Class C2 limits (EN 61800?3).

Active Line Modules

Active Line Modules can supply energy and return regenerative energy to the supply system. Braking Modules and braking resistors are required only if the drives need to be decelerated in a controlled manner after a power failure – i.e. when energy cannot be regenerated into the line supply. In contrast to Basic Line Modules and Smart Line Modules, however, Active Line Modules generate a regulated DC voltage which remains constant despite fluctuations in the line voltage. In this case, the line voltage must remain within the permissible tolerance range. Active Line Modules draw a virtually sinusoidal current from the supply which limits any harmful harmonics.

In order to operate an Active Line Module, it is absolutely essential to use the Active Interface Module for the appropriate rating. A line filter can be installed optionally to restrict conducted interference to Class C2 limits (EN 61800?3).

Please refer to the System Description for more information about designing a drive system with SINAMICS S120.

Power Modules, Motor Modules and Line Modules are available in booksize, booksize compact, blocksize and chassis formats:

• Power Modules in blocksize and chassis formats
• Motor Modules and Line Modules in booksize, booksize compact and chassis formats.

Cooling methods

Depending on the format, there are several cooling options for crane applications:

SINAMICS S120 booksize, cooling methods

Internal air cooling

In this standard solution, the power loss from the electronics and power units of the drive components is removed by natural cooling or by a forced-ventilation system and routed to the interior of the control cabinet.

External air cooling

External air cooling uses the "through-hole" method. The components' power unit heat sinks pass through the mounting surface in the control cabinet and can thus release the heat losses of the power circuit to a separate external cooling circuit. The only heat loss that remains in the cabinet is emitted by the electronics. Degree of protection IP54 can be achieved at this "mechanical interface". The heat sink, with its cooling fins and the fan unit (part of the scope of supply), protrudes through the back into a separate ventilation area, which can also open outwards.

Cold plate cooling

Units designed with cold plate cooling can pass the power unit heat losses to an external heat sink via a thermal interface on the unit's rear panel. This external heat sink is water-cooled, for example.

Energy efficiency

The SINAMICS S120 drive system saves energy by recovering energy from the axes and using it within the DC link group of a multi-axis configuration and by feeding it back into the supply system. Even at full infeed capacity, no unnecessary heat is generated in the control cabinet. Because the Active Line Modules prevent capacitive and inductive reactive currents, SINAMICS S120 also ensures that no unnecessary power losses occur in the power supply and that no current harmonics occur. This not only prevents detrimental effects on other loads, but it also reduces the heat generated in the control cabinet.

System components

System components are divided into the following categories:

• DC link components
  e.g. Braking Modules and braking resistors
• Load-side power components
  e.g. motor reactors
• Supplementary system components
  e.g. Terminal Modules, Operator Panels and Communication Boards
• Encoder system interface
  for connecting various types of encoders to SINAMICS S120

Booksize format

Booksize format units are optimized for multi-axis applications and are mounted adjacent to one another. The connection for the shared voltage-source DC link is an integral feature. The booksize format offers the full range of cooling options for crane applications: internal air cooling, external air cooling and cold plate cooling.

Booksize compact format

Derived from the booksize format we developed the booksize compact format for machines with particularly high requirements for the compactness of their drives. The booksize compact format combines all benefits of the booksize format and provides the same performance with an even smaller overall height and an extended overload capability. The booksize compact format is thus particularly well suitable for integration into machines with high dynamic requirements and confined installation conditions.

The booksize compact format has the same design for the cooling methods of internal air cooling and cold plate cooling.

Blocksize format

Blocksize format units are optimized for single-axis applications and are supplied only as Power Modules.

The CU310?2 Control Unit can be snapped onto them directly. The units are cooled by internal air cooling or liquid cooling.

Chassis format

Higher-output units (approximately 100 kW (150 HP) and above) are constructed in chassis format. These are available as Line Modules, Power Modules and Motor Modules. Chassis format units are cooled by an internal air cooling circuit. The CU310?2 Control Unit can be integrated in the Power Modules.