They have been designed with a zone concept and therefore offer the highest possible level of operational reliability. EMC measures have been rigorously implemented. With the help of simulated conditions, partitions have been designed to act as air guides and heat dissipation units.

Special measures used in the construction of the cabinets ensure that they remain mechanically durable over their entire life cycle.

Attention has been paid to providing a wide range of cable routing options and special design concepts are applied consistently to broaden the scope of application and simplify servicing. The units have all the necessary connections and connecting elements. Thanks to their carefully considered configuration concept, cabinets are shipped in a ready-to-connect state or, in the case of multiple transport units, have been prepared for quick assembly. The selection you make is supported by an extensive range of options, harmonized and coordinated to various applications.

All components, from individual parts to the ready-to-connect cabinet, undergo rigorous testing throughout the entire production process. This guarantees a high level of functional reliability during installation and commissioning, as well as in operation.

The design of replaceable components is based on the principle that they must be quick and easy to change. In addition, the "SparesOnWeb" Internet tool makes it easy to view the spare parts that are available for the particular order ¹⁾.

¹⁾ The properties of the SINAMICS S120 Cabinet Modules described in this catalog are not transferable to cabinet units constructed to meet the requirements of specific applications.

Line Modules

Power is fed to the drive line-up via Line Modules, which generate a DC voltage from the line voltage and, therefore, supply energy to the Motor Modules connected to the DC link. They are suitable for connection to grounded TN/TT and non-grounded IT systems.

The Line Modules are connected to the line supply system via Line Connection Modules and are equipped as standard according to Category C3. Category C3 is part of the "second environment" (in accordance with EN 61800-3). The second environment are locations outside residential areas or industrial sites which are supplied from the medium-voltage network via a separate transformer.

The range of Line Modules has power ratings from 132 kW to 900 kW (380 V to 480 V) and from 250 kW to 1500 kW (500 V to 690 V). Furthermore, up to four identical Line Modules can be connected in parallel in order to increase the power rating.

For a compact configuration, Line Connection Modules up to input currents of 3200 A are available. Two Line Modules can be operated in parallel on these Line Connection Modules.

The following types of Line Module are available:

• Basic Line Modules
• Smart Line Modules
• Active Line Modules

Basic Line Modules

Basic Line Modules are designed only for infeed operation, i.e. they are not capable of recovering energy to the mains supply.

If regenerative energy is produced, e.g. when the drives brake, then 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, a line reactor appropriate to the supply conditions must be installed. Line reactors are generally required if two or more Basic Line Modules are operated in parallel on a common supply system in order to increase power.

For this reason, line reactors are installed in the appropriate Line Connection Module as standard.

If, for example, a converter transformer is used to connect to the line supply (12-pulse operation), line reactors might not be required and they can be optionally omitted (order code L22).

In the case of parallel connection, versions with line-side fuses are available for selective protection of the individual Basic Line Modules.

Smart Line Modules

Smart Line Modules can supply energy to the DC link 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 necessary line reactor is included in the device as standard.

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. However, 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.

Active Line Modules must always be used in conjunction with an Active Interface Module. Active Interface Modules include the required pre-charging circuit for the Active Line Module in addition to a Clean Power Filter. For SINAMICS S120 Cabinet Modules, these two components are always regarded as a single unit.

In the example, two units comprising an Active Interface Module and Active Line Module are connected in parallel to jointly supply the DC link.

DC link components

Braking Modules enable braking resistors to absorb the regenerative energy produced during drive deceleration, which is then converted into heat.

Braking Modules as a Line Module or Motor Module option

For lower braking powers, Braking Modules are available with continuous braking powers up to 50 kW. These Braking Modules are ordered as an option for the Line Modules and Motor Modules (order codes L61/L64 (25 kW) or L62/L65 (50 kW), refer to the description of the options).

Central Braking Modules

For higher continuous braking powers, separate Central Braking Modules are available. These modules are used centrally in the drive line-up.

Motor Modules

There are two different types of Motor Module available with the SINAMICS S120 Cabinet Modules drive system.

Booksize Base Cabinets with Booksize Cabinet Kits

Motor Modules at the low end of the power range from 1.6 kW to 107 kW (380 V to 480 V) can be implemented as Booksize Cabinet Kits installed in Booksize Base Cabinets. In the 1.6 kW to 9.7 kW power range, Booksize Cabinet Kits are available as Double Motor Modules, which combine two inverters in a single module.

Chassis Cabinets

Each Chassis Cabinet is fitted with one SINAMICS S120 Motor Module in chassis format and covers the power range from 75 kW to 1200 kW (380 V to 480 V or 500 V to 690 V). The power rating can be extended up to approx. 4500 kW by connecting up to four Motor Modules in the chassis format in parallel.

SINAMICS S120 Motor Modules, chassis format and Cabinet Modules can also be used as a braking module, if, instead of a motor, a 3-phase braking resistor is connected.
For more detailed information, please refer to the SINAMICS Low Voltage Engineering Manual.

System structure

Line Modules are coupled with the various Motor Modules by means of prefabricated busbar sets with different current carrying capacities.

All standard busbars, as well as electronics components, are protected against environmental influences. This is achieved through the use of nickel-plated copper bars and painted modules throughout.

A special, standard auxiliary power supply system supplies the individual Cabinet Modules with the required auxiliary voltages for the power components, fans and 24 V loads.

These voltages are preferably generated using an auxiliary power supply module. Additional supply possibilities are available using the K76 option (auxiliary power supply generation in the Line Connection Module) or using an external supply in the auxiliary power supply system.

The auxiliary power supply system comprises an auxiliary power supply module with two terminal blocks and a 24 V DC fuse as well as the required connecting cables. It is supplied completely assembled and ready to operate. Only the cable connections to the adjacent Cabinet Module must be established on-site.

Communication between the Control Unit, power units and other active SINAMICS components is realized via DRIVE-CLiQ connections.

DRIVE-CLiQ is an internal serial interface of the drive that enables fast and easy configuration of the complete drive line-up with prefabricated cables in varying lengths.

The Cabinet Modules can be optionally supplied in pre-configured transport units up to a total length of 2400 mm . This option is recommended in particular for Line Modules together with Line Connection Modules since, in this case, the Line Connection Module must be equipped with a pre-charging DC link or line reactors (depending on the type of Line Module), in addition to the electrical interface (busbar). Transport units enable the various devices to be quickly and easily assembled on-site.

Varnished PCBs

The following drive units are equipped as standard with varnished PCBs:

• Chassis format units
• Control Units
• Sensor Modules
• Terminal Modules
• Advanced Operator Panel (AOP30)

The varnish coating on the modules protects the sensitive SMD components against corrosive gases, chemically active dust and moisture.

Nickel-plated busbars

All of the copper busbars used in the converter cabinets are nickel-plated in order to achieve the best possible immunity to environmental effects. Further, the bare copper connections do not have to be cleaned for customer connections.

Note: For technical reasons, some parts of the copper busbars are not nickel-plated for some of the options.

Degrees of protection of Cabinet Modules

The EN 60529 standard covers the protection of electrical equipment by means of housings, covers or equivalent, and includes:

• Protection of persons against accidental contact with live or moving parts within the housing and protection of the equipment against the ingress of solid foreign matter (touch protection and protection against ingress of solid foreign bodies)
• Protection of the equipment against the ingress of water (water protection)
• Abbreviations for the internationally agreed degrees of protection

The degrees of protection are specified by abbreviations comprising the code letters IP and two digits.

Cabinet Modules fulfill the criteria for degree of protection IP20 as standard. The other degrees of protection outlined here are available as an option.