Specification of components for connection system

To complete the drive system, components such as motors and encoders must be connected to it via cables.

For motors with DRIVE‑CLiQ interface, the DRIVE‑CLiQ cables carry the 24 V DC power supply. On all other Sensor Modules, a separate 24 V DC power supply must be provided.

Drive connection system

DRIVE‑CLiQ cables are available in different versions and lengths (see section MOTION-CONNECT connection systems).

The required bending radii apply particularly to short cables. In addition to the distance between the two DRIVE‑CLiQ sockets that the cable is to connect, a cable length of at least 60 mm (2.36 in) must be added to allow for bending radii. When defining lengths of pre-assembled cables, see section MOTION-CONNECT connection systems.

Unused DRIVE‑CLiQ sockets can be sealed with a blanking plug to prevent the ingress of contaminants. Suitable blanking plugs are supplied in the accessories pack for the units.

Mechanical configuration of the drive

A SINAMICS S drive line-up comprises a Line Module, Motor Modules, DC link components, a Control Unit, and the optional expansion modules.

Configuration of a drive line-up in booksize format

The following criteria must be taken into account when a drive line-up of booksize format units is configured:

• The Smart Line Modules 5 kW and 10 kW must always be arranged on the left as the first module. All other Line Modules should be arranged on the left as the first module. The CU320-2 Control Unit in this case can be "snapped onto" the left-hand side of the Line Module.
• The DC link busbars can be connected on the right and left with Basic Line Modules, Active Line Modules and Smart Line Modules rated 16 kW and larger. In this case, the modules can be arranged in reverse order (from right to left) or on both sides (see arrangement for units in chassis format).
• Only one Line Module is permitted in each drive line-up.
• A number of drive line-ups must be configured for power supplies which cannot be provided by the highest rating.
• The Motor Modules must be arranged beside the Line Module in descending order of the rated currents, that is, the Motor Module with the highest rated current is to be mounted immediately adjacent to the Line Module, and the Motor Module with the lowest rated current is positioned furthest away from the Line Module.
• DC link busbars are integrated in the Line Modules, Motor Modules, Braking Modules, Capacitor Modules and Control Supply Modules so that the modules can be connected to the drive line-up. The current carrying capacity of the integrated DC link busbars is determined by the module rating and is either 100 A or 200 A (see technical specifications). It must be ensured that the DC link busbars have the required current carrying capacity at every point within the drive line-up. When high-output Motor Modules (DC link busbars 200 A) and low-output Motor Modules (DC link busbars 100 A) are used, for example, the Braking Module (DC link busbars 100 A) must be installed downstream of the high-output Motor Modules.
• DC link adapters can be used to implement multi-tier configurations.
• The drive line-ups should be configured such that the total length of all power cables for the motor cables and the line cable, which should preferably be shielded, in each individual line-up does not exceed the permissible total cable length.

Power-oriented arrangement of booksize format Motor Modules

• The Control Unit configuration is flexible. The following configuration options are possible:
  • "Docking" on the left-hand side of the Line Module
  • Direct mounting next to the drive line-up on a mounting plate
  • Mounting in other cabinet panels taking into account the permissible DRIVE‑CLiQ cable lengths

Configuration of a drive line-up in chassis format

• The Motor Modules must be positioned to the left or right of the Line Module with decreasing rated currents (i.e. the Motor Module with the highest rated current is positioned next to the Line Module, while the Motor Module with the lowest rated current is at the end on the left or right). You must ensure that the cables/busbars for the DC link meet the current-carrying capacity requirements for all connected Motor Modules.
• The inductance of the DC link busbars must be low, achieved, for example, by arranging the bars as close as possible in parallel, but observing the required creepage distances and air gaps.
• The Control Unit configuration is flexible. The following configuration options are possible:
  • "Docking" on the left-hand side of the Line Module
  • Direct mounting next to the drive line-up on a mounting plate
  • Mounting in other cabinet panels taking into account the permissible DRIVE‑CLiQ cable lengths

Configuration of a mixed drive line-up in chassis and booksize formats

A mixed drive line-up must be configured according to the rules for chassis format units. The Motor Modules in booksize format can be connected to the higher-level DC link busbars by means of DC link rectifier adapters. There are two possible connection options - A and B. With A, each Motor Module in booksize format is connected using the appropriate DC link rectifier adapter. With B, Motor Modules in booksize format are connected to one another and the internal DC link busbars and a DC link rectifier adapter are used on the last Motor Module to make the connection to the higher-level DC link busbars. In the latter case, the DC link rectifier adapter must be attached to the last Motor Module on the right-hand side of the line. As regards the arrangement of modules with different current ratings, the guidelines specified under "Configuration of a drive line-up in booksize format" also apply to mixed drive line-ups.

Ideally, the entire length of the higher-level DC link busbars can be dimensioned for the rated DC link current of the Line Module. The busbars are then protected by the line fuses at the infeed end.

If the cross section of the DC link busbars or cabling is reduced, this branch must be designed to be short-circuit-proof. The current limiting mechanism of the Motor Modules connected to the branch with reduced cross section then protects it against overloading. It is not advisable to reduce busbars or cables down to the mandatory minimum cross section. No additional overload protection (fuse) is required on the assumption that overloading cannot occur as a result of cable damage on the cable route to the Motor Module and that the circuit branch is protected against overloading by the Motor Module.

Where the cross section has been significantly reduced, or the circuit design is not inherently short-circuit-proof, a branch fuse must be installed at the beginning of the section with reduced cross section in order to protect the DC link connections involved. In the event of a fault, the fuse must be capable of interrupting DC fault currents; other types of miniature circuit breaker are not suitable.

Allocation of branch fuses for option (A) in a supply system with grounded neutral (TN system). The calculations are based on the assumption that П„ = L/R < 10 ms applies to the time constant П„ in the DC fault circuit and that the fault current is interrupted by the fuse after maximum 1 s.