Why Siemens DC drives carry the best reputation worldwide

SINAMICS DC drive technology

Siemens DC drive technology has helped increase efficiency and reduce engineering costs for decades. Featuring an advanced design that greatly facilitates configuration, installation, integration, commissioning and service, SINAMICS DC drives are perfectly aligned with DC motors, are highly dynamic, and increase overall system reliability. And Siemens continues to be the world leader in DC drives innovation, as demonstrated by the new SINAMICS DCP bidirectional DC/DC converter products being employed in many power-intensive industrial and smart-grid applications.

SINAMICS DCM drives Siemens DC drive solutions allow you to significantly reduce technology costs by delivering peak performance and integrated intelligence for maximum availability - such as the parallel switching interface for redundant operations, flexible expandability, quick and easy component exchange, easy commissioning and parameterization, and integration in a range of automation schemes.

News & announcements for SINAMICS DCM drives

SINAMICS DCM Devices with Functional Safety were exhibited for the first time in November 2018 at the SPS/IPC/Drives trade fair in Nuremberg, Germany. This new functionality is certified by TÜV (German Technical Inspectorate) for Safe Torque Off (STO) and Safe Stop 1 (SS1).

Effective October 1, 2017, SINAMICS DCM Cabinets will be canceled as products and will no longer be actively marketed. A 4-year phase-out period has been established.

Four new CUD kits are now available for SINAMICS DCM DC Drive Products that bundle the available control units and connector boards at a reasonable cost..

The SINAMICS DCM base drive range has been extended above the existing 1200 A DC maximum offering by adding 20 new Base Drives (10 2Q and 10 4Q) that range from 1,500 A to 2,800 A DC.

SINAMICS DCM base drive packages are available to simplify the engineering process of sizing, selecting and coordinating accessory components required to assemble armature, field and control power circuits when building a DC drive system using a SINAMICS DCM DC converter

Introduction

Many of the same tools and components so successful in SINAMICS AC technology are now made available for SINAMICS DC drives. This series of drives sets itself apart as a scalable drive system - both for basic as well as demanding and sophisticated applications. For the standard closed-loop control, the DC converter is equipped with a standard control unit for converters (standard CUD). For applications demanding a higher computational performance and interfaces, the system can be expanded by an advanced CUD.

The SINAMICS DC Master series combines the open-loop and closed-loop control and power units in one device and therefore offer a compact, space-saving design. The AOP30 Advanced Operator Panel and the BOP20 Basic Operator Panel are available for commissioning and local operator control. The interfaces of the CUD and the number of digital inputs and outputs can be supplemented using additional modules - such as the TM15 and TM31 Terminal Modules.

Learn more

Download the SINAMICS DCM brochure

SINAMICS DCM features

PROFIBUS, PROFINET, and EtherNet/IP communications options
Single-phase connection is possible for units ≤ 125 A
Variance of control units
Field power supply in-line with requirements in the field
24 V DC electronics power supply
Power unit is insulated with respect to ground
Free function blocks are integrated in the standard version and Drive Control Chart
Functionality can be expanded using SINAMICS components
Coated boards and nickel-plated copper busbars (optional)
Wide temperature range

Overview of strengths

Intelligent

Free Function Blocks
can be optimally adapted to an application’s requirements for drive-related open-loop and closed-loop control functions (e.g. winder, sectional drive, load sharing, master-slave, cross-cutter, etc.) in a decentralized manner that relieves the workload on higher level controls
Flexible expandability in functionality and performance
The extensive product range and the many options allow the SINAMICS DCM to be optimally adapted to customer requirements - both technically and economically. Different customer requirements relating to the computational performance and speed can be precisely fulfilled with the ability to select between a Standard CUD, an Advanced CUD - or a combination of both

User friendly

Simple commissioning and parameterization
Menu-assisted at the AOP30 Advanced Operator Panel with graphics-capable LCD display and plain text display or PC-supported using the STARTER commissioning tool
Simple integration into automation solutions
Comprehensive range of communication interfaces: PROFIBUS, PROFINET, EtherNet/IP,™ standard Ethernet TCP/IP
Reduced training time and expense
The maximum number of identical components is reduced as a result of the extensive product range of SINAMICS DC MASTER. The seamless and integrated series of SINAMICS DC MASTER Units encompasses a wide current and voltage range. The series of drives is designed to be connected to three-phase line supplies

Reliable & available

Reliability and robustness
The highest degree to ensure maximum production
Highest dynamic performance
Increased productivity and finished product quality
Plant or system availability increased by being able to quickly and simply exchange components
Components have been designed so that they can be quickly and easily replaced. The available spare parts are assigned to the serial number of the drive unit
Global support and availability
Large network of qualified system integrators, distributors and Siemens professionals for consultation, design, commissioning, service and support worldwide

Technical introduction to SINAMICS DCM drives

basic ratings

Operation	2Q and 4Q
Power range	5– 40,000 Hp (6.3 kW - 30 MW)
Rated DC current	15 – 3,000 A (single converter)
Rated supply voltage	3-ph. 85 to 950 V AC
Rated field DC current	3 – 40 A (optional: 85 A)
Rated frequency	45 – 65 Hz
Degree of protection	IP00
Standards	IEC, EN, DIN, VDE, UL, cULus, NEMA, UL 508 C, GOST

Visit the SINAMICS drives applications site

SINAMICS DCM industries and applications

Cranes & hoists

Hoisting gear
Boom-hoist
Motor-generator sets
Gantry
Holding gear
Field supplies
Trolley gear
Closing gear
Magnet supplies
Slewing gear
Elevators
Luffing gear
Positioners

Metals, mining, metalforming

Continuous casters
Tandem mill main drives
Cold mill coiler
Levelers
Metal presses
Crank shears
Roughing mill main drives
Skin pass mill main drives
Magnet supplies
Wire-drawing machines
Slitters
Table rolls Accumulators
Flying shears
Finishing mill main drives
Down coilers
Pinch rolls
Brush rolls
Motor-generator sets
Cold mill main drives
Payoff reel
Bridle rolls
Squeegee rolls
Field supplies
Cranes, elevators and hoists
Z-mill main drives Up coilers Deflector rolls Edgers
Coil box rolls Cross-cutters

Plastics & rubber

Banbury mixers
Coaters
Pullers
Winders
Re-spoolers
Calenders
Laminators
Core pullers
Sectional drives
Rotary knifes
Extruders
Embossers
Slitters
Feeders
Flying shears
Agitators
Compounders
Scorers
Conveyors
Cross-cutters
Pelletizers
Mixers
Perforators
Heat sealers

Pulp & paper

Winders
Web accumulators
Synchronized drive control
Laminators
Gluers
Cross-cutters
Automatic roll change-splice control
Sectional drives
Wet sections
Calenders
Die cutters
Rotary knifes
Tension control
Felt sections
Slitters
Embossers
Traversing drives
Load sharing
Dryer sections
Scorers
Flying saws
Positioning drive
Coaters
Folders
Perforators
Corrugators

Introduction

SINAMICS DCM - DC drives - control module

The SINAMICS DC MASTER Control Module offers the optimum solution when retrofitting and modernizing existing DC drives. Unlike the SINAMICS DC MASTER Drive, which comprises open-loop / closed-loop control and power unit, the Control Module is used solely as a component of modernization. There are many plants and systems with DC technology, which in their present condition can no longer be coupled with state-of-the-art automation systems, like Totally Integrated Automation. In retrofitting or upgrading, the existing motor, mechanical system and power unit may be retained and only the control unit is replaced by the Control Module. This allows for a state-of-the-art DC drive at an extremely favorable price with the full functional scope of the well-proven, fully digitized units from the SINAMICS DC MASTER series.

The flexible design, as well as the available pre-assembled cable harnesses and mounting components, simplify integration into existing plants and systems. Adaptation to the configuration and to the power data of the existing components is realized through simple parameterization. By using an Advanced Operator Panel AOP30, a favorably priced alternative is obtained to control cabinet measuring instruments. Using a compact space-saving design, the SINAMICS DC MASTER Control Module, which includes a field power unit, may be split depth-wise to allow even better utilization of the mounting/installation space.

SINAMICS DCM control module features

Variance of the Control Units
24 V DC electronics power supply
Integrated field power unit
Free function blocks integrated into the standard version and Drive Control Chart
Functionality may be expanded using SINAMICS components
Compact design and can be split depth-wise
Coated boards and nickel-plated copper busbars optional
Wide temperature range
PROFIBUS, PROFINET, EtherNet/IP™ connectivity options
Suitable protective measures (among others IT-Security, e.g. network segmentation) have to be considered to ensure safe operation of the plant

Technical introduction to SINAMICS DCM control modules

basic ratings

* Supply voltage can lie below the rated supply voltage - the actual rated value can be parameterized. This applies to both the armature as well as the field circuit
Connecting rated supply voltages of the armature circuit, power unit	3 AC 50 / 125 / 250 / 575 / 1000 V
Rated supply voltage for electronics	DC 24 V (DC 18 to 30 V); I_n = 5 A
Rated field supply voltage *	2 AC 480 V (+10 / -20 %)
Rated frequency	45 to 65 Hz
Rated DC field voltage	max. 390 V
Rated DC field current	40 A

Typical applications

The main applications for the SINAMICS DC MASTER Control Module include the retrofit and modernization of DC drives in existing plants and systems, especially high-rating drives using DC technology. There are many older systems that still employ analog technology that cannot be easily or affordably connected to a state-of-the-art automation system.

Introduction

The SINAMICS DC Master (DCM) Base Drive from Siemens is an extremely flexible and cost-effective solution for both new installations and retrofits where space is limited. This pre-wired solution comes complete and tested with all the necessary components mounted on a back panel. SINAMICS DCM Base Drives are ideal for end-users and third-parties such as Siemens Solution Partners and system integrators.

The DC Base Drive has been around for over 25 years, beginning with the third generation 6RA22 digital DC drives, circa 1986. The SINAMICS DCMBase Drive is unique in that the DC I rating of the Converter is used for each panel design. Advantages with SINAMICS over the previous two generations include more power per panel in the same footprint making it easy to retrofit existing legacy base drive installations. In addition, in new installations where 150% overload is not needed (i.e. MG Set Field supplies), the SINAMICS DCM Base Drive offers a significant cost advantage.

The Standard base drive range includes base drives that are rated from 15 A to 1200 A DC continuous current
The Extended base drive range includes base drives that are rated from 1500 A to 2800 A DC continuous current

SINAMICS DCM base drives features and benefits

Features

Standard base drive range: 3 to 800 HP in DCI rating or up to 500 HP with DCII rating as a pre-engineered, standard design - minimizing engineering and delivery times
Extended base drive range: 1250 to 2500 HP in DCI rating or up to 2000 HP with DCII rating as a pre-engineered, standard design – minimizing engineering and delivery times
DC converter — includes Advanced Control Unit DC (CUD), communication board – PROFINET, EtherNet/IP and standard Ethernet TCP/IP (CBE20), micro memory card and Basic Operator Panel (BOP20)
450-1200A converters include a single phase fan at 230V AC as standard
1500-2800A converters include a three phase fan at 480V AC as standard
Fusing — input fuses, field fuses, DC output fuse for regenerative units
Control power transformer
AC contactors line side 15-850A, DC loop contactor >1200A
UL508A certification
65KA SCCR rating

Benefits

Increased productivity
High-dynamic performance
Decreased project cost
Reduced maintenance costs
Easy- to-install
Pre-wired and tested for easy startup
Converters can be replaced without changing the panel
Drop in replacement for 6RA24 and 6RA70 base drives
More current per panel than previous generations
SINAMICS options are easy to add
125 A and below base drives can be run at single-phase incoming supply with drive de-rating

Technical introduction to SINAMICS DCM base drives

Basic ratings

	15 – 1,200 A DC	1,500 – 2,800 A DC
Supply voltages and output ranges	240V / 480V 3-phase AC, +10/-20% : 3 to 800 Hp < 125A base drives can be run at single-phase AC with 30% de-rate	575V 3-phase AC: +10/-20% : 1,250 to 2,250 Hp 690V 3-phase AC: +10/-20% : 1,250 to 2,500 Hp 830V 3-phase AC: +10/-20% : 1,750 to 2000 Hp 950V 3-phase AC: +15/-20% : 2,500 Hp
Supply systems	Grounded or ungrounded	Grounded or ungrounded
Rated line frequency	45 – 65 Hz	45 – 65 Hz
Output voltage	0 – 500V DC	575V 3-phase AC: 0 – 600V DC 690V 3-phase AC: 0 – 725V DC 830V 3-phase AC: 0 – 875V DC 950V 3-phase AC: 0 – 1000V DC
Overload possibility	Max. 1.8x rated DC current	Max. 1.8x rated DC current
Short circuit current rating	SCCR per UL508A: 65 kA	SCCR per UL508A: 65 kA
Type of enclosure and color	IP00	IP00
Type of cooling	Self–ventilated / forced-air ventilation	Forced-air ventilation
Noise level LpA (1 m)	70 – 74.4 dB(A) at 60 Hz line frequency	75.6 dB(A) at 60 Hz line frequency
UL listing	UL and cUL (508A), drive components are listed UL508C	UL and cUL (508A), drive components are listed UL508C
Ambient temperature	32 to 113˚F (0 to +45˚C)	32 to 104˚F (0 to +40˚C)
Relative humidity (non-condensing)	5 – 95%	5 – 95%
Installation altitude	Up to 3,300 ft (1,000 m) above sea level without de-rating	Up to 3,300 ft (1,000 m) above sea level without de-rating

Configure and order SINAMICS DCM

Using the Siemens Drive Configurator, you can simply and quickly configure your SINAMICS DCM drive system and then order it through Industry Mall.

DC power converters – SINAMICS DCP With SINAMICS DCP Siemens starts a new generation bidirectional DC/DC converter. Siemens combines its expertise in DC technology with the advantages of the proven SINAMICS family. Thus it sets standards when it comes to quality, reliability and technical functionality.

Introduction

SINAMICS DCP, a scalable DC-DC Power Converter suited for both industrial and smart grid applications, is a combined buck / boost converter in one device. Overlapping voltage ranges at the input and output are possible by means of 4Q operation. This means that the DC output voltage can be lower or higher than the DC input voltage and for variable voltage levels, current can flow in both directions making SINAMICS DCP the ideal solution for charging and discharging batteries and supercapacitors.. Thanks to its high switching frequency, SINAMICS DCP is very compact and lightweight.

The high efficiency of SINAMICS DCP maximizes the overall energy fed into the public grid, island grid, microgrid or the internal power system of a factory when it is used to interconnect DC energy sources (e.g. photovoltaics, fuel cells) and energy storage systems (e.g. rechargeable batteries, SuperCaps) to the common DC bus of a grid converter/infeed inverter such as a SINAMICS S120 Active Line Module.

A PROFIBUS communication interface is included as standard. The communications interfaces of the Advanced CUD can be supplemented using additional modules - such as the optional CBE20 for PROFINET or EtherNet/IP™.

The BOP20 basic operator panel is available for simple commissioning and local operator control.

STARTER software is used for the parameter assignment and diagnostics.

Learn more

Download the SINAMICS DCP brochure

SINAMICS DCP characteristics

SINAMICS DCP controls the electrical power flow between two Direct Current systems
SINAMICS DCP can be operated with current control or voltage control
SINAMICS DCP’s main application is to control the electrical power flow between two DC systems, e.g. between a common DC bus and a stationary battery
– from the common DC bus (DCP input, terminals P1 and N1) to a battery (DCP output, terminals P2 and N2) – this is called motoring operation and means positive current
– from the battery (DCP output, terminals P2 and N2) back to the common DC bus (DCP input, terminals P1 and N1) – this is called generating operation and means negative current
Bidirectional power flow is possible
The voltages of both DC systems may have any values between 0 and +800V
The voltages in the two DC circuits are independent of one another
The electrical power flow, controlled by a signed (+ or -) current setpoint specification, is possible regardless of the voltages in the two DC circuits (in the nominal range)
The current setpoint and control signals can be specified via fieldbus (PROFIBUS – standard; PROFINET or EtherNet/IP – optional via CBE20 Communication Board) or hardwired signals

Features & benefits

SINAMICS DCP features	User benefits
Combined buck/boost converter in one device	Optimized adaption to energy storage systems and the common DC bus of an infeed inverter or grid converter
Bidirectional	Energy flow in both directions, charge and discharge a battery or supercapacitor with one device
High efficiency - up to 98.6%	Maximum energy harvest
Wide voltage range	Along with bidirectional power flow capability and high efficiency, SINAMICS DCP provides an optimal interconnection of energy storage systems (rechargeable batteries, SuperCaps) to the common DC bus of a grid converter, such as an Active Line Module Different infeed sources (solar, fuel cells, wind, etc.) can be connected to the common DC bus of an Active Line Module, via SINAMICS DCPs and Motor Modules, and realize a multi generator system
Scalable power from 30 to 480 kW	High currents by connecting up to 4 devices in parallel at the input and / or output
High switching frequency	Low current ripple and high voltage quality Compact and lightweight design, control unit and reactors are built-in
High flexibility with 4Q operation	A 4Q converter can be applied as a boost or as a buck converter where the DC output voltage can be lower or higher than the DC input voltage, e.g. charging and discharging a battery Allows overlapping voltage ranges at the input and output
High maximum voltage 1,000 VDC (Imax = 5 A for 30 sec, every 5 min. (only 30 kW DCP)	To connect PV arrays under no-load conditions
Functionality can be expanded using additional SINAMICS drive components, e.g., SINAMICS S120 Active Line Module	Different infeed sources (solar, wind, etc.) can be connected together to realize a multi generator system
Integrated systems from one source	Well-known and easy operating philosophy from the SINAMICS AC and DC drives family

Technical specifications

	30 kW DCP	120 kW DCP
Voltage range	0 - 800 VDC
Maximum voltage range	1,000 VDC (Imax = 5 A for 30 sec, every 5 min)	920 VDC (with derating)
Power	30 kW @ Imax = 50 A, Vin = Vout = 600 V DC	120 kW @ Imax = 200 A, Vin = Vout = 600 V DC
Scalability	4x parallel, input and / or output
Maximum efficiency	> 98%
Communication	PROFIBUS, PROFINET, EtherNet/IP™, DRIVE CLiQ with OALINK connection to CU320-2
Closed-loop control	Current, voltage and power
Control module	Own control unit
Protection degree	IP20	IP00
Certifications / approvals	CE, cURus, EAC, RCM
Standards	IEC 62109-1 IEC 61800-5-1 IEC 61800-3 UL 508C UL 61800-5-1 CSA C22.2 No. 274

Software functions

Voltage control (even in parallel operation)
Constant voltage based on a setpoint, can be used as an adjustable voltage source
Extended voltage range: 0 V – 800 V DC
Voltage as low as 0 V to charge SuperCaps
Parametrizable battery charging characteristic
Optimum adaptation to various types of battery chemistries and their varying charging requirements
Voltage regulation on DC bus
Highest process reliability by maintaining and controlling the DC bus voltage
Automatic DC bus buffering
Fast supply of the DC bus from a battery, in case of line supply failure to an infeed unit (SINAMICS S120 ALM), to maintain uninterrupted operation of a motor connected to a frequency converter (SINAMICS S120 Motor Module)
Variable pulse frequency
To reduce switching losses, optimize efficiency and control current ripple
Temperature controlled fans (only available for 120 kW DCP)
To optimize efficiency in partial –load range and reduce noise
Three selectable overload profiles
Power peaks can be briefly provided, peak shaving applications can be realized
- Increased current, 0 - 20%, (available for 30 kW DCP and 120 kW DCP)
- Low overload (only available for 120 kW DCP)
- High overload (only available for 120 kW DCP)
Parametrizable overload reaction based on heat sink temperature
Derating of switching frequency, derating of current or switch-off
EtherNet/IP™ industrial communication interface
To integrate into other automation networks
Local adjustment of voltage and current actual values via control unit
The voltage and current values that the DCP displays can be adjusted so that they correspond to externally measured values
Input of an external temperature sensor via control unit
Three different temperature sensors possible
Integrated Maximum Power Point (MPP) Tracker
To maximize the power yield of Photovoltaic arrays
PV array flying restart
The no-load voltage of a PV array can be drawn into the continuous running duty range of SINAMICS DCP

Four-quadrant considerations

Overlapping voltage ranges at the input and output are possible by means of 4Q operation

The main application of SINAMICS DCP is to control the electrical power flow between two DC systems:

From a DC bus (input side 1, terminals P1 & N1) to a stationary battery (output side 2, terminals P2 & N2).
This is called motoring operation and means positive current
From a battery (output side 2, terminals P2 & N2) back to the DC bus (input side 1, terminals P1 & N1).
This is called generating operation and means negative current

The power flow in both directions (from the DC bus to the battery and from the battery to the DC bus) is called bidirectional.

The voltages in the two DC circuits are independent of one another.

The electrical power flow, controlled by a signed (+ or -) current or power setpoint specification, is possible regardless of the voltages in the two DC circuits (in the nominal range).

Definition of a 4-quadrant converter

A 4Q converter can be applied as a boost or buck converter
The DC output voltage can be lower or higher than the DC input voltage, i.e. charge and discharge a battery
P1, N1 (DC Bus – Input) and P2, N2 (Battery – Output) refer to the input and output terminals of the converte

	Input voltage terminals P1, N1	Output voltage terminals P2, N2	Voltage flow	Battery
Q1	Higher	Lower	Input >> Output	Charging
Q2	Higher	Lower	Output >> Input	Discharging
Q3	Lower	Higher	Output >> Input	Discharging
Q4	Lower	Higher	Input >> Output	Charging

Typical applications for SINAMICS DCP

Industrial energy efficiency

Alternative to braking choppers, e.g. crane & hoist applications
When a load is lowered, excess energy can be temporarily stored in rechargeable batteries or SuperCaps. As a consequence, this stored energy can then be used for the next hoisting operation instead of being simply wasted using a braking resistor. As a consequence, for electric crane applications, a significant amount of energy can be saved; and for diesel-powered crane systems, a smaller diesel generator can be used
Coupling DC buses at different voltage levels
DC buses at different voltage levels can be intelligently coupled. As a consequence, only one infeed point (grid converter such as an Active Line Module) is required
Battery test stands
Using the bidirectional DC-DC converter, battery test stands can be implemented to test the performance of batteries / rechargeable batteries
Mining conveyor belts
SINAMICS DCP is especially interesting for conveyor belts in the mining sector, as connected energy storage devices (Batteries, SuperCaps) can be used to store energy when braking, which can later be utilized to cover load peaks. This means that smaller diesel generators can be used and operated at their optimum operating point, with the corresponding reduction in costs and fuel consumption

Battery storage solutions / energy management

BESS (Battery Energy Storage Systems)
To implement stationary battery energy storage systems by connecting battery modules to the DC-DC converter. The energy is then fed into the grid or standalone supply via a common DC bus and a grid converter
Wind and photovoltaic
To buffer excess energy from wind turbines and PV systems - the excess energy is temporarily stored in batteries.
- SINAMICS DCP is also suitable for exciting synchronous generators from a DC bus
Electric vehicle infrastructure - electric cars, buses, trains, boats, etc.
for charging and discharging batteries in a stationary infrastructure