Standardized, comfortable engineering with SIZER and STARTER

As with all SINAMICS drives, the SIZER configuring tool helps

you to select the optimal drive configuration for your application. Graphical support and wizards efficiently guide you
through the selection of necessary components based on your
application.
SINAMICS S120 AC Drives are commissioned using STARTER,
the commissioning tool for the SINAMICS family. Electronic
rating plates ensure automatic and error-free preconfiguration of the drive system. Automatic optimization is a simple
way of optimizing the control response. It ensures fast and
reliable commissioning of the drives.

SINAMICS S120 CUA31 Control Unit adapte

It is also possible to use SINAMICS S120 AC Drives in multi-axis
applications. The drive is connected to a CU320 Control Unit via
the DRIVE-CLiQ interface using the CUA31 Control Unit Adapter.
The CU320 Control Unit then takes over the drive functions for
the AC drive. SIMOTION D modules can be used as a Control
Unit for motion control applications which go beyond the scope
of positioning tasks. SINAMICS S120 AC Drives can also be used
in hybrid operation with SINAMICS S120 multi-axis units in this
configuration (Figure 2). This provides maximum flexibility for
the use of SINAMICS S120 units.

SINAMICS S120 CU310 Control Unit

The use of a SINAMICS S120 AC Drive in a single-axis application
connected to a higher-level control is illustrated in Figure 1. Each
of the AC Drives is equipped with a CU310 Control Unit. This unit
contains the field bus interface for connecting to the higher-level
control. CU310 DP with a PROFIBUS DP connection or CU310 PN
with an integrated PROFINET interface can be selected. In both
cases communication between the control and the drive takes
place in accordance with the standardized PROFIdrive profile.
CU310 offers functions ranging from the simple speed controller to full positioning functionality. Drive-related inputs/outputs
can easily be linked in the CU by means of BICO technology. This
permits the greatest possible options for drive and higher-level
control.
Drive-related inputs/outputs can be linked via the integrated I/O
interface. An integrated TTL/HTL interface and a DRIVE-CLIQ interface are available as encoder interface. For a version with an
integrated motor this encoder interface features the advantage
of an electronic rating plate.
It is easy to implement safety systems using the currently available integrated safety functions such as “Safe standstill” (STO),
“Safe brake control” (SBC) and “Safe stopping” (SS1).

SINAMICS S120 AC Drive

 SINAMICS S120 AC Drives – a building block
for integrated drive solutions
SINAMICS S120 is a modular drive system with Servo and
Vector Control and is the SINAMICS product most suitable for
demanding drive applications. The stand-alone SINAMICS
S120 AC Drives complement the DC/AC units, which use a
common infeed and controller designed especially for
multi-axis applications. Optimally tailored, integrated solutions can be designed for any type of application based on this
building block system.
The ready-to-connect SINAMICS single drive
SINAMICS S120 AC Drives are designed for single-axis applications but can also be used for multi-axis applications.
Positioning tasks can be reliably executed as well as synchronous movements and motion control tasks. In multi-axis
applications with spatially distributed drives, distributed
solutions based on SINAMICS S120 AC Drives offer a practical
alternative to a central drives line-up.
Universally implementable
SINAMICS S120 AC Drives can easily be implemented in conjunction with higher-level automation systems using field bus
interfaces and the standardized PROFIdrive profile. Solutions
to standard positioning tasks – especially in the SIMATIC PLC
environment – can therefore be found using SINAMICS S120
AC Drives even without in-depth knowledge of drives.
Because it is so easy to combine SINAMICS S120 AC Drives
with other SINAMICS S120 units, multi-axis groupings can be
extended comfortably and economically.
Modular machine components can thus be adapted to high
levels of integration and flexibility in line to varying customer
requirements.
Flexibility through modularity
Every SINAMICS S120 AC Drive is a combination of a Power
Module and a selectable Control Unit or Control Unit Adapter.
An optional filter can also be integrated.
If the AC Drive is operated as a stand-alone single-axis drive,
a Control Unit (e.g. CU310 DP) is added to the Power Module.
It contains the entire control intelligence for the drive, including positioning functions and the field bus interface.
If the AC Drive is combined with other SINAMICS S120 units
to build an integrated multi-axis drive solution, a CUA31 Control Unit Adapter is added to the Power Module in order to
connect the AC Drive to a central Control Unit (e.g. CU320 or
SIMOTION D) via the DRIVE-CLiQ interface in accordance with
the SINAMICS S120 system architecture.
With SINAMICS S120 the modular expansion of your machines
is never limited. Cost-optimized and specific solutions are
ensured since only the components and functions required for
a perfect fit solution are used.

SINAMICS S120 – technical data

Modules and expansion options:
Components for every application
•  Control modules (Control Units) handle drive and
technological functions spanning axes and provide
the central link to higher-level controls
•  Motor Modules operate as inverters - supplying
the connected motors
•  Line Modules centrally feed power into the DC
link, regenerate into the line supply and compensate any line fluctuations
•  Power Modules for AC Drives combine power infeed and power module in the form of a unit that
is ready to be powered up
•  Electronic options extend the functionality and
cover various interfaces to encoders and process
signals
•  DC link components are optionally used to stabilize the DC link voltage
•  Line-side power components – such as fuses,
contactors, reactors, filters – round off the system
•  High dynamic performance and precise: 32-bit
technology
•  Fast: Short current rise times
•  Universal: For synchronous and induction motors
•  Rugged: High overload factor
•  Safe: Safety Integrated
•  Flexible and simple: BICO technology
•  Plug & Play: DRIVE-CLiQ makes it possible

SINAMICS S120 in plant construction

•  Drive versions can be flexibly developed
•  Scalable power
•  Ready-to-connect Cabinet Modules
•  Chassis units for integration into
cabinets
•  Low costs for training, engineering
and commissioning
•  Simple to replace, spare parts inventory, logistics
•  Low life cycle costs through energy
saving and low maintenance costs
•  Highest possible security of investment

ac-drives The perfect solution – quickly and reliably

Complete drive groups can be interlinked
and assembled using the SINAMICS S120
Cabinet Modules and Chassis units. This
is because it is possible to combine module types with freely selectable power
ratings as required. Fast and straightforward, due to the standard interfaces that
are harmonized with one another.
For paper machines, rolling mills, test
stands and cranes – that typically require
multi-motor applications with high power
ratings, both the modular cabinet units as
well as also the Chassis units are the ideal
solution as part of a modular system.
The highly flexible, modular system follows the trend to shift intelligence into
the drive, which is achieved using its harmonized, standard interfaces. Planning is
simplified and reliability increased thanks
to the ready-to-connect cabinet solution
with several Cabinet Modules. The chassis
design of the SINAMICS S120 is the ideal
approach for companies that wish to engineer their own chassis-type solutions.

SINAMICS S120 Cabinet Modules: modular cabinet concept for multi-motor drives

A modular cabinet system is available
in the form of the SINAMICS S120
Cabinet Modules. These can be used
to engineer almost any drive solution
for multi-motor drive systems in plant
construction. Thanks to the standard
interfaces, the modules can be interlinked and combined to quickly con -
fig ure ready-to-connect drive solutions up to 4,500 kW.
•  High degree of flexibility through
the finely scalable power and module types as well as an extensive
range of options
•  Extremely compact drive solution
that is ready to be connected
•  DC coupling using prefabricated
busbar sets
•  Data is coupled through DRIVE-CLiQ
•  Fast and reliable installation and
commissioning
•  Short delivery times and lower
ordering time and costs

SINAMICS S120 and SINUMERIK solution line – the innovative solution for processing machines

SINUMERIK solution line and
SINAMICS S120 form the ideal system
platform for the machine tool construction sector. Thanks to the scalable hardware and software, SINUMERIK solution
line opens up almost limitless application
opportunities. Whether for basic turning
or milling applications, highly complex
tasks and high-speed applications,
in woodworking and glass processing
or when handling transfer lines –
SINUMERIK solution line is the perfect
solution for the widest range of requirements in processing machines.
Its essential features include the distributed, simplified system architecture and the
expanded diagnostic capabilities down to
the component level. SINUMERIK solution
line is completely integrated into the
SINAMICS communications structure.

SINAMICS S120 and SIMOTION – the perfect team for production machines

Increasingly, complex motion control
tasks must be handled in machinery
construction and at the same time, they
must be able to run even more precisely
and faster. This is where the SIMOTION
motion control system and the high-performance SINAMICS S120 drive system
form a perfect team. SIMOTION D, the
version that is physically integrated into
the SINAMICS S120 drive, is the ideal solution for machines with a high number
of axes and where high requirements are
placed on the precision. This distributed
automation structure allows the machine
to be subdivided into various axis groups
that are controlled from one SIMOTION
motion control system. Communications
between SIMOTION systems is either established via PROFIBUS DP or PROFINET.
In this case, there is another important
aspect – the compact machine design,
which is due to the distributed automation structure and the Motion Control
Unit that is directly integrated in the
drive.

Totally Integrated Automation – Setting standards in productivity

Totally Integrated Automation with
SINAMICS S120
•  TIA: Unified, sector-specific automation solutions
•  PROFIBUS and PROFINET are integral
components of TIA
•  Motion control with SIMOTION
•  Numerical control with SINUMERIK
The basis for customized automation
solutions
With its Totally Integrated Automation
(TIA), Siemens is the only manufacturer
that offers a seamless range of products
and systems for all industry sectors –
from a single source. Harmonized to the
individual customer requirements, based
on TIA, efficient industry sector-specific
automation solutions can be implemented. Lower life cycle costs when oper ating machines and systems and considerably shorter times to market result in
significant increases in productivity and a
higher investment security.
Straightforward: Totally Integrated
Automation with SINAMICS S120
In addition to SIMATIC, SIMOTION and
SINUMERIK, SINAMICS also belongs to the
core components of Totally Integrated
Automation. For instance, the STARTER
commissioning tool is an integral component of TIA. All of the automation solution components can be parameterized,
programmed and commissioned using a
unified engineering platform within the
same environment. The integrated data
management ensures consistent data and
simple archiving of the complete plant or
machine project.

CUA31/32 Control Unit Adapter for multi-axis applications with SINAMICS S120 AC Drive

The drive is coupled to e. g. a CU320
multi-axis Control Unit through the CU
Adapter CUA31 via a DRIVE-CLiQ interface. In this collection, SINAMICS S120
AC Drives can also be used together with
SINAMICS S120 multi-axis drive units.
This collection provides the highest
degree of flexibility when using
SINAMICS S120 Drives.
When compared to the CUA31, the
CUA32 additionally has an HTL/TTL
encoder interface to connect up an
external encoder.

Motion control integrated in the drive: SIMOTION D410 Control Unit

The SIMOTION D410 Control Unit is the
ideal solution if, going beyond the pure
control intelligence, motion control is
required for an axis and PLC functionality
in a compact package. SIMOTION D410
can be used for single-axis applications
– such as winders, crosscutters or feed
equipment – but also in synchronous
groups for modular machine concepts.
In this case, the machine module, automated using SIMOTION D410, receives
the leading value from a higher-level
control and synchronizes its axis to this
leading value.
Either the D410 DP with PROFIBUS DP
connection or D410 PN with integrated
PROFINET port can be used.
Up to four fast cam outputs or three measuring probe inputs can be implemented
using the onboard inputs/outputs.

Central control intelligence with interface to the control: Control Unit CU310

The AC Drives have a CU310 Control Unit
to couple them to the higher-level control. They offer a functional scope extending from a basic speed controller up to
extensive positioning functions.
Either a CU310 DP with PROFIBUS DP port
or CU310 PN with integrated PROFINET
port can be selected. Drive-related inputs/
outputs can be simply connected to the
CU using BICO technology. This permits
the highest possible decoupling between
the drive and the higher-level control.
Also for the AC drives, when necessary,
an additional encoder and drive-related
I/Os can be connected through
DRIVE-CLiQ.

SINAMICS S120 – AC Drives for single-axis applications

AC Drives for
single-axis applications
•  An autonomous single-axis
SINAMICS S120 AC Drive comprises
a Control Unit and Power Module
•  Alternatively, a Power Module can
be integrated into a multi-axis
group via CU adapter
•  Power Modules are available in the
Blocksize and Chassis formats
Typical applications
Single-axis drives are suitable for applications in all sectors, such as e.g. for travel
drives, centrifuges, elevators and extruders as well as for mixers and kneaders.
Single-axis SINAMICS S120 AC Drives are
also the ideal solution for multi-axis applications where the drive axes are located remotely from one another. The same
applies to modular machine concepts
that are being increasingly implemented
in the packaging and woodworking industries.
For a single-axis drive, the line supply
infeed and the power supply of the motor are combined in one device – the
so-called Power Module. For single-axis
applications, a special Control Unit (e.g.
CU310) mounted on the Power Module
handles the drive control; for multi-axis
applications a Control Unit is used (e.g.
CU320) coupled through DRIVE-CLiQ.
In the latter case, instead of the Control
Unit, a CU Adapter is mounted on the
Power Module.
For instance, SINAMICS S120 AC Drives
decentrally coupled to a higher-level
control via PROFIBUS DP or PROFINET can
reliably handle e.g. positioning tasks in
automated assembly machines and handling systems.

SINAMICS S120 DC/AC drive units for multi-axis applications

SINAMICS S120 DC/AC drive units
for multi-axis applications
The modular drive configuration for
multi-axis applications consists of:
•  One Control Unit with the complete
drive intelligence (including interface to the higher-level controls or
HMI devices)
•  One Line Module for the central
power infeed
•  One or several Motor Modules to
control the power
•  Simple, straightforward cabling
using DRIVE-CLiQ
•  Optional Terminal Modules to connect encoders and drive-related I/Os
•  All interfaces communicate through
pre-fabricated cables
•  Drive components are detected
using electronic rating plates
•  Motor Modules and Line Modules
are available in the Booksize Compact, Booksize and Chassis formats

commissioning: STARTER tool

STARTER is the standard commissioning
tool for all drives in the SINAMICS family.
The commissioning engineer can even
transparently configure and optimize complex systems in a short time. STARTER is
available in three installation variants: As
stand-alone version, integrated in Drive ES
for applications with SIMATIC or integrated
in SCOUT for applications with SIMOTION.

SINAMICS S120 – functions for increased efficiency

•  Basis functions: Speed and torque
control, positioning functions
•  Intelligent starting functions for
automatic restart after a power
interruption
•  BICO technology with interconnection to drive-related I/Os
•  Graphic configuring with free blocks
using DCC to adapt the drive system
in a user-friendly fashion to the machine environment
•  Integrated safety functions to costeffectively implement safety concepts
•  Controlled infeed / regenerative
feedback to avoid undesirable
harmonics fed back into the line
supply, regenerative feedback when
braking and for an increased degree
of ruggedness with respect to line
supply fluctuations

SINAMICS S120 Range of power ratings

SINAMICS S120
Range of power ratings
•  AC/AC single-axis and DC/AC multiaxis drive units
•  Power range: 0.12–4,500 kW
•  Line supply voltages 230 V,
380–480 V and 660–690 V
(50/60 Hz)
•  Servo, vector control, V/f control
•  Induction and synchronous motors
(incl. torque and linear motors)

SINAMICS S120 for high-performance single- and multi-axis applications

The modular system for highperformance applications
The innovative SINAMICS S120 hardware
and software concept tackles sophisticated drive tasks in industrial applications
with a power range extending from 0.12
through to 4,500 kW:
SINAMICS S120 offers high-performance
individual AC/AC drives in the Blocksize
and Chassis formats as well as coordinated DC/AC drives for multi-axis applications in the Booksize Compact and Chassis formats and Cabinet Modules.
Increased flexibility with central
control intelligence
For SINAMICS S120, the drive intelligence
is combined together with the control
functions in Control Units (CU), which
handle both vector and servo control as
well as V/f control. For all drive axes, they
also handle the speed and torque control
as well as additional intelligent drive
functions.
Performance can be freely selected for
vector and servo controls
SINAMICS S120 vector control is recommended for drive solutions involving continuous material webs – for instance,
wire drawing, foil making and paper machines – as well as for hoisting gear, centrifuges and marine drives with harmonious, rotary motion. Servo control with
SINAMICS S120 is used for cyclic processes with precise and fast closed-loop
position control using servomotors. For
instance, this includes applications in the
packaging and printing industries as well
as machine tools.

The SINAMICS S120 drive system

High degree of flexibility for successful
machine concepts
As a member of the new SINAMICS drive
family, the SINAMICS S120® drive is part
of the modular drive system for high-performance applications in machinery and
plant construction. SINAMICS S120 offers
high-performance single- and multi-axis
drives for an extremely wide range of industrial applications.
Through its scalability and flexibility,
SINAMICS S120 perfectly fulfills the
growing requirements relating to the
number of axes and performance.
SINAMICS S120 allows flexible machine
concepts to be created, which can be
used to quickly implement specific
customer requirements.
The response to increasing demands
Today, machines must be able to be
manufactured more cost-effectively and
at the same time they should offer operating companies increasingly higher levels
of productivity. The SINAMICS S120 drive
concept fulfills both of these tasks! Engineering times are shortened due to the
fact that it can be engineered in a userfriendly fashion. Its high dynamic performance and accuracy permits higher cyclic
machine rates for a maximum
degree of productivity. Not only this, its
simple handling and maintenance increases the degree of availability and reduces the life cycle costs. When considering
everything: SINAMICS S120 increases the
competitiveness of both machine manufacturers and operating companies.
Modularity for machine construction
SINAMICS S120 allows power and control
performance to be freely combined.
Multi-axis drive solutions with higherlevel motion control can be implemented
using the modular SINAMICS S120 drive
system just the same as solutions involving single-motor drives. This means that
the machines can be designed to be
fully modular therefore addressing the
growing number of different versions.
Where modules or individual components
are to be combined or innovated,
SINAMICS S120 guarantees the perfect
compatibility between all of the system
components without requiring any major
engineering costs.
Applications in machine and plant
construction
SINAMICS S120 means increased
machine performance in many sectors –
whether continuous material webs or
cyclic and high-dynamic processes, for
instance in:
• Packaging machines
• Plastics machines
• Textile machines
• Printing machines
• Paper machines
• Handling and assembly systems
• Machine tools
• Rolling mills
• Test stands

Digital microprocessor-controlled power converter technology

Digital microprocessor-controlled power converter technology, both for DC and AC drives, has
now reached a level of technical sophistication
which (in purely technological terms) enables
almost any drive job to be handled both with DC
and AC drives. Nevertheless, the conventional
DC drive (in both its 1-quadrant and 4-quadrant
variants) will continue to play an important role,
for technical and physical reasons alike, when
dynamic drives with a constant load torque and
stringent requirements for overload withstand
capability throughout a large speed setting range
are involved.

Efficiency and operating point of DC and AC standard motors

The motor constant makes it possible to design the nominal point of DC motors corresponding to the process requirements.
However the efficiency of AC motors is better (> 55 kW: approx. 1 ... 4 % depending on cooling method).
DC motors are often utilized according to insulation class H. Standard AC motors are used to be utilized according to insulation
class B. This results in a possible higher efficency with AC motors.

Degree of protection for motors, Ac Dc Motor

The historical development of the DC motor as an electric variable-speed drive since the beginning of the twenties has meant
that DC motors are customarily used with internal/forced ventilation (approx. 85 % of VSDs ≤ 250 kW).
For variable-speed AC drives, asynchronous standard motors have predominantly been utilized since the 70s/80s, which mostly
feature surface ventilation (approx. 90 % of VSDs ≤ 250 kW). Thus the process of matching the three-phase standard motors
to the requirements applying for variable-speed drives with AC converters has not yet been concluded.
The fact that AC motors with ratings of up to approx. 1400 kW are supplied in degree of protection IP 54 as standard is a tribute
to their simple and sturdy construction. For drive jobs in hazardous areas, explosion-protected AC motors are used almost
exclusively. This means that the AC motor has won itself a firm position and proved its practical utility most especially in those
sectors of industry characterized by aggressive ambient conditions and a high degree of dirt and dust in the cooling air.

High speed setting range at constant power (field weakening operation or field control range)

For specialized drive jobs, like coiler drives, test rigs, winders and unwinders, etc., very large setting ranges at constant power
are stipulated. In these cases, conventional field weakening operation with an externally excited DC machine makes
implementation particularly cost-efficient. This means: the larger the speed range in which a motor can output its maximum
power (length of the horizontal section of the characteristic in Fig. 5, from nG
 to n
1
), the smaller the overdimensioning factor
can be kept Pmax(motor)
/ Pmax(load)
.
Values obtained from empirical feedback:
A typical value for the field weakening range of DC Motors
with a shaft height of 112 ... 225 mm in the rating category of
5 ... 360 kW (M ≤ 2900 Nm) is 1 : 3.
The maximum value for the field weakening range at compensated DC motors with a shaft height of ≥ 250 mm in the
rating category of 125 ... 1400 kW (M = 2400 ... 24500 Nm)
is 1 : 5.
Example: compensated DC Motor DMA + 280 K (see Fig. 5)
nG
n
1
nmax
Speed n (rpm) 0 500 1500 2500
Power P (kW) 0 130 130 80
Torque (Nm) 2483 2483 827 305
Values obtained from empirical feedback:
Due to the pull-out torque  Mk
 ≈  MN
  x  2,5, the  typical value
for the field weakening range is only 1 : 1.5 up to a maximum
of 1 : 2.5 for all standard AC Motors.
Example: AC Standard Motor ...450LL12 (see Fig. 5)
nG
nmax
Speed n (rpm) 0 500 1250
Power P (kW) 0 130 130
Torque (Nm) 2483 2483 933

Mains pollution: ac drive

The line currents of DC drives with a 6-pulse thyristor bridge will always contain, in addition to the fundamental wave, the 5th,
7th, 11th and 13th harmonics with empirical values of 22 %, 14 %, 9 %, 7.6 % , referenced to the fundamental wave. In the
case of several DC drives operating simultaneously on the mains, the different phase sequences of the harmonic currents will
produce a "statistical improvement" in the level of mains pollution.
Due to the dimensioning method adopted for the smoothing inductors, harmonic currents with contents of 40 %, 14 %, 9 %
and 7.6 % must be anticipated with AC drives featuring a 6-pulse diode bridge in 1-quadrant drives. Due to the identical phase
angle of the harmonic currents, several drives on the same mains can be regarded as one drive with the same total current.This
also applies for thyristor bridges in 4-quadrant operation.
Input bridges with IGBT switching elements enable the low-frequency harmonics to be substantially reduced, but conversely
create more high-frequency harmonics.

Reactive-power demand

Both drive concepts (AC and DC) take reactive power from the mains. Its size is negligible in the case of AC drives, and is RPMdependent below the rated speed with DC drives. The AC drive is the more favourable option here.
Values obtained from empirical feedback:
For AC drives, the value for cos ϕ
1
 is in
1-quadrant applications
with diode bridge cos ϕ
1
 ≈ 0.99
4-quadrant applications
with thyristor bridge and
with energy recovery into the mains cos ϕ
1
 ≈ 0.9
Values obtained from empirical feedback:
For DC drives, the value for cos ϕ
1
 is in
1-quadrant applications cos ϕ
1
 ≈ 0...0.9
4-quadrant applications cos ϕ
1
 ≈ 0...0.85

Modernization of existing DC drive

When it comes to the question of whether it is worth while
modernizing an existing DC drive or less expensive to replace
it entirely with an AC drive, there are also various arguments
which need to be assessed:
Basically, there are several options available for a modernization job:
1. Replace the entire DC drive (converter and motor) by a new
DC drive.
2. Replace only the converter cubicle, if the motor is still in
good condition.
3. Replace the converter module by a modern digital unit.
4. Replace the old, analog drive electronics by new, digital
electronics while continuing to use the power section
(recommended only for ratings above 1 MW).
5. Replace the entire drive system with a new AC drive.
When answering the question of what approach constitutes
the optimum solution in a particular case, the following main
criteria are important:
Will the requirements for the drive change in future (load
requirements, environmental conditions)?
In what condition are the individual components of the
system (reliability, age, maintenance outlay)?
How far will the supply conditions change in future?
Before a decision is made to modify a drive from DC to AC
design, the following points should be taken into consideration:
Outlay for new power cabling.
Space requirements for converter cubicles.
Dissipation of energy losses from the switchroom sufficient?
Foundations, mounting for motor sufficient?
Space requirement for new motor.
Duration of conversion work.

Price comparison DC and AC drive systems

(unit + motor or complete switchgear cabinet  + motor)
Based on the present-day development status of DC and AC drive engineering, and taking into account all the
systems' advantages/disadvantages mentioned above, the following guideline figures can be given:
1-quadrant drives <40...80 kW ê AC drives less expensive
4-quadrant drives >40...60 kW
(AC converter +  braking resistor; see Fig. 10); ê DC drives less expensive
Regenerative 4-quadrant drives > 15 kW ê DC drives less expensive