Simply the world's best drive system for demanding single-axis or multi-axis servo applications
SINAMICS S120 high performance modular drive system
With a wide range of coordinated components and functions in a complete drives package, SINAMICS S120 modular drives are designed for motion control and a spectrum of high-performance drive applications in mechanical and systems engineering. SINAMICS S120 drives include high-performance single drives and coordinated drives (multiple-axis applications) with vector or servo functionalities that allow implementation of customized high performance drive solutions for the ultimate in flexibility and increased productivity. In addition to an innovative system architecture and digital communication options, these drives come in a variety of designs and cooling types, delivering performance from 0.16 to 6,000 HP, and featuring efficient engineering and quick commissioning.
Flexibility for virtually any high-performance application
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 Booksize, Compact, Chassis, and Cabinet Modules. The different SINAMICS S120 versions can be combined as required through the DRIVE-CLiQ interface. For instance, Line Modules in the Chassis format can be combined with Motor Modules in the Booksize format to address multi-axis applications with a high total power rating.
Jump to
- Typical applications
- Overview of strengths
- What's new? All inside S120 web server technology
- SINAMICS S120 system architecture: response to meet increasing demands
- SINAMICS S120 components: mix & match with a host of combination options
- SINAMICS S120 cooling concept
- More technical information for SINAMICS S120
- Downloads & support
- Video introductions to SINAMICS S120 booksize format
- SINAMICS S120 in America - case studies & success stories
- Easy configuration & ordering
SINAMICS S120
Regardless of whether the application involves continuous material webs or cyclic, highly dynamic processes – SINAMICS S120 means increased machine performance in many industries, including packaging and printing machines, machines for the processing of plastics, textiles, paper and wood, cranes and hoisting gear, handling and assembly systems, machine tools, rolling mills, test stands and machines in the renewable energy sector.
SINAMICS S120 can be found in higher-functioning pumping applications, such as:
Continuous motion
- Eccentric worm pumps
Discontinuous motion
- Hydraulic pumps
- Dosing pumps
- Descaling pumps
SINAMICS S120 can be found in medium to complex moving applications, such as:
Continuous motion
- Elevators
- Container cranes
- Mine hoists
- Open cast mine excavators
- Test stands
Discontinuous motion
- Accelerating conveyors
- Rack feeders
- Crosscutters
- Roll changers
- Roller feeds
- Engaging / disengaging
SINAMICS S120 can be found in processes with high speed and torque accuracy, such as:
Continuous motion
- Extruders
- Winders / unwinders
- Leading / Following drives
- Calenders
- Mechanical presses
Discontinuous motion
- Servo presses
- Rolling mills
- Multi-axis motion control – cam discs, interpolation
SINAMICS S120 can be found in applications requiring positioning of individual or multiple coordinated axes, such as:
Continuous motion
- Printing machines
Discontinuous motion
- Robotics
- Pick & place
- Indexing tables
SINAMICS S120 is the "go to" drive for all applications in material processing, such as:
Continuous motion – main drives for
- Drilling
- Sawing
- Turning
- Milling
- Gear cutting
- Grinding
Discontinuous motion – axis drives for
- Sawing
- Turning
- Milling
- Drilling
- Laser machining
- Gear cutting
- Grinding
- Nibbling / punching
From basic to advanced drive functions to application and industrial know-how, the SINAMICS S120 system features firmware functions no other drives can beat. Highlights include Safety Integrated Functions, know-how protection, and as this video describes – SINAMICS integrated web server technology, which offers extremely user-friendly diagnostics and maintenance.
SINAMICS S120 formats and their specifications
SINAMICS S120 includes individual AC / AC drives as well as coordinated DC / AC drives for multi-axis applications. The system architecture offers significant advantages when it comes to developing innovative machine concepts:
- Flexible development of drive variations for all industry sectors, applications, and markets using the scalability of the modular system and by connecting the components through DRIVE-CLiQ
- Highest possible return on investment
High performance single-axis applications
Single-axis drives are suitable for many applications — for example, travel drives, centrifuges, elevators and extruders, as well as 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 each other. For single-axis drives, the line infeed and the power supply of the motor are combined in one device – the Power Module. The closed-loop drive control is handled by a special Control Unit, such as CU310-2, mounted on the Power Module. Alternatively, a power module can be integrated into a multi-axis lineup via a CU adapter.
The blocksize format for SINAMICS S120 uses the PM240-2 power module, featuring:
- Significant space savings in the control cabinet as a result of increased power density, as well as side-by-side mounting
- Increased ruggedness through longer motor cable lengths and by meeting increased environmental requirements such as now having a SIL3 rating (frame size D, E, F only) and extended standard temperature ranges
- Lower costs for installation and maintenance through an optimized connection system
- Lower system costs by eliminating the need for input and output reactors — shield connection plates are also included with each unit
- Expanded product flexibility by having six built-in safety functions
- Push-through mounting for frame sizes A, B and C (larger frame sizes coming soon)
With its separate power unit and control unit, the SINAMICS S120 chassis 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 DRIVE-CLiQ digital system interface.
The following drive units are available in the chassis format:
- Power modules
- Basic line modules
- Smart line modules (only available in air-cooled version)
- Active line modules
- Active interface modules
- Motor modules
High performance multi-axis applications
DC / AC devices set themselves apart as a result of the modular design. The complete drive intelligence is embedded in the Control Units (CU). They handle all of the closed-loop control functions in the drive lineup. Additionally they execute all of the other drive functions, for example logically combining drive-related I/O, positioning functions etc. – and have PROFIBUS DP or PROFINET as central interfaces to connect to higher-level automation systems. Depending on the selected Line Module type, energy can be fed back into the three-phase line supply, the DC link voltage can be controlled and line harmonics reduced. Energy is exchanged between motoring and generating Motor Modules via the central DC link. Only the missing or excess energy is drawn from or injected back into the line supply – or is dissipated in braking resistors. Drive-related inputs/outputs can be expanded using Terminal Modules
Advantages of DC / AC Drives
- One control unit – with the complete drive intelligence (including the interface to higher-level controls or HMI devices)
- Line module (infeed converter) – to provide the DC link voltage from the three-phase line supply
- One or several Motor Modules – to control the Motors
- Optional I/O modules – to connect encoders and drive-related inputs and Outputs
- Simple wiring – using DRIVE-CLiQ
- All interfaces communicate – using preconfigured cables
- Drive components are detected – using electronic type plates
- Motor modules and Llne modules – in both booksize and chassis formats
The popular booksize format for SINAMICS S120 offers numerous advantages in terms of flexibility, space-usage, ease of use, safety, and more
- Optimized for multi-axis applications and interconnected via common DC link
- Comprised of a control unit (e.g. CU320-2, SIMOTION, SINUMERIK) as well as infeed and motor modules
- Available in booksize format: active line module, active interface module, basic line filter, smart line module, line reactor, line filter, single motor module, double motor module, braking module, braking resistor, capacitor module, control supply module, DC link adapter
- New and improved motor module connections in C (continuous) and D (discontinuous) designs save space, offer higher power density, and feature easier and better wiring
With its separate power unit and Control Unit, the SINAMICS S120 chassis 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 DRIVE-CLiQ digital system interface.
The following drive units are available in the chassis format:
- Power modules
- Basic line modules
- Smart line modules (only available in air-cooled version)
- Active line modules
- Active interface modules
- Motor modules
Enclosing SINAMICS S120 features and benefits
SINAMICS S120CM is a modular system to configure enclosed drive line-ups with a central line infeed (rectifier) and common DC bus supplying power to multiple motor modules (inverters).
Cabinet Module line-ups are typically used for…
- Multi-motor coordinated drive systems such as for paper machines, rolling mills, certain test stands and cranes
- Very high Hp single drives
- To supplement SINAMICS G150 and S150 stand-alone enclosed drives
SINAMICS S120CM is available in both NEMA and IEC versions.
Maximize servo functionality while minimizing space and cabling
The distributed servo drive in the SINAMICS S120 series rounds off the SINAMICS drive portfolio and offers a high degree of freedom when it comes to new and existing machine concepts. It consists of a compact ready-to-connect drive unit featuring:
Synchronous servomotor with multiturn absolute encoder
Integrated power unit (motor module)
The SINAMICS S120M gives the option to move the power unit out of the control cabinet and is directly integrated with the motor on the driven servo axis. This provides advantages and a high degree of flexibility regarding existing and new machine concepts. The innovative hybrid cable reduces cabling and connects back to the central SINAMICS S120 components utilizing the adapter module 600 (AM600).
Strengths & benefits
- Compact ready-to-connect drive unit with integrated power element
Reduction of control cabinet space and footprint - Relocation of the power module into the machine
Reduced space and need for air cooling in control cabinet - Single-cable solution through preconfigured hybrid cable
Reduced costs for cabling and reduced cable lengths - Reduced space requirements with retrofit in the control cabinet
Increases the flexibility in case of retrofit - SINAMICS S120M is part of the SINAMICS S120 system
Identical Look & Feel. All safety and communication functions provided in the SINAMICS S120 system are available
Typical applications
Machines that extend over large areas
Limited control cabinet envelope dimensions
Machines with limited cabinet space
Specifications
Control Unit (CU) modules represent the central intelligence of an SINAMICS S120 drive system. In addition to the basic functions – such as operating system, communication and closed-loop control – they also include the user configuration.
Control Unit CU310-2 central control intelligence with interface to the control system
AC / AC Drives are each equipped with a CU310-2 control unit for coupling to a higher-level control. It offers functions from a basic speed controller up to extensive positioning functions. CU310-2 DP with PROFIBUS DP connection or CU310-2 PN with integrated PROFINET interface are available. Drive-related inputs/outputs in the Control Unit can be simply combined using BICO technology. As a consequence, the highest possible degree of decoupling between the drive and higher level control system can be achieved. For AC / AC Drives, when required, an additional encoder and drive-related I/O can be connected via DRIVE-CLiQ.
Control unit adapter CUA31 / 32 for mixed multi-axis applications
The drive is connected to a multi-axis control unit, such as CU320-2, using the CU adapter CUA31 via the DRIVE-CLiQ interface. This control unit then handles the drive functions for the AC-Drive. In this configuration, SINAMICS S120 AC / AC Drives can also be used in mixed operation with SINAMICS S120 multi-axis devices, facilitating maximum flexibility. In comparison to the CUA31, the CUA32 also has an integrated HTL/TTL encoder interface to connect an external encoder.
Single-axis control unit CU310-2
SIMOTION D410-2 motion control for AC/AC drives used in a multi-axis setup
This is the SIMOTION D variant for single-axis applications with multi-axis option in blocksize format.
The SIMOTION D410-2 control units are specially designed for use with the SINAMICS S120 PM240-2 power modules in blocksize format and can be directly connected to the power modules of this series.
Control Unit CU320-2 – the brains at the heart of SINAMICS S120's coordinated motion control
Essentially designed for multi-axis operation, the communication, open-loop and closed-loop control functions for the line module one or more motor modules are executed in a CU320‑2 Control Unit.
The computing capacity required increases in proportion to the number of connected Motor Modules and system components and in relation to the dynamic response required. For the CU320‑2 Control Unit, the performance expansion is necessary from the 4th axis. The utilization of the CU320‑2 Control Unit can be calculated with the SIZER for Siemens Drives engineering tool.
Multi-axis control unit CU320-2
SIMOTION D4x5-2 Control Units
The SIMOTION D425-2, D435-2, D445-2 and D455-2 Control Units feature PLC and Motion Control performance (open-loop control and Motion Control) for up to 16, 32, 64 or 128 axes, as required.
The integrated drive control enables each D4x5-2 Control Unit to operate up to 6 servo, 6 vector or 12 V/f axes.
The integrated drive control is based on the drive control of a SINAMICS S120 CU320-2 Control Unit (firmware version V4.x/V5.x) and supports servo control (for a highly dynamic response), vector control (for maximum torque accuracy) and V/f control.
SIMOTION D4x5-2 Control Units
In three configuration levels, the SINUMERIK NCU 710, 720 and 730 in SINAMICS S120 booksize format are the drive controller interface for the SINUMERIK 840D sl line of CNC controllers.
The configuration levels address the machining/computing complexity demanded of the system.
The line module provides the DC link voltage from the 3-phase line supply.
Basic, Active, Smart
- Basic Line Modules are available for applications in which no energy is returned to the supply or where the energy exchange between motor and generator axes takes place in the DC link. Basic Line Modules are designed for connection to grounded TN/TT and non-grounded IT supply systems
- Active Line Modules: the self-commutated infeed/regenerative feedback units with IGBTs generate a regulated DC link voltage. This means that the connected Motor Modules are decoupled from the line voltage. Line voltage fluctuations within the permissible supply tolerances have no effect on the motor voltage
- Smart Line Modules are infeed/regenerative feedback units that supply power to connected Motor Modules. Furthermore, they are capable of feeding regenerative energy back into the grid. The infeed occurs over a diode jumper, while stable, line-commutated regenerative feedback takes place via IGBTs with 100 % continuous energy regeneration. The regenerative capability of the modules can be deactivated by means of parameterization
Active interface modules (AIM)
- Active Interface Modules, used in conjunction with Active Line Modules, contain a Clean Power Filter with basic RI suppression, the pre-charging circuit for the Active Line Module, the line voltage sensing circuit and monitoring sensors
Basic, Active, Smart
- Basic Line Modules are used for applications in which no energy is returned to the supply or where the energy exchange between motor and generator axes takes place in the DC link. Basic Line Modules can only feed energy from the supply system into the DC link, energy cannot be fed back into the supply system. The DC link voltage is directly derived from the 3-phase line voltage via a 6-pulse bridge circuit. Basic Line Modules are suitable for connection to grounded, star TN, TT and non-grounded symmetrical IT supply systems. The connected Motor Modules are pre-charged over the integrated pre-charging resistors (20 kW and 40 kW) or through activation of the thyristors (100 kW)
- Active Line Modules are self-commutated infeed/regenerative feedback units (with IGBTs in the infeed and regenerative feedback directions) that generate a controlled DC link voltage. This means that the connected Motor Modules are decoupled from the line voltage. Line voltage fluctuations within the permissible supply tolerances have no effect on the motor voltage. Active Line Modules are designed for connection to grounded star (TN, TT) and non-grounded symmetrical (IT) supply systems.
- Smart Line Modules are stall-protected, line-commutated infeed/regenerative feedback units (diode bridge for incoming supply; stall-protected, line-commutated regenerative feedback via IGBTs) with 100 % continuous regenerative feedback power. The regenerative feedback capability of the modules can be deactivated by means of a digital input (Smart Line Modules 5 kW and 10 kW) or by means of parameterization (Smart Line Modules 16 kW, 36 kW and 55 kW). Smart Line Modules are designed for connection to grounded TN/TT systems and non-grounded IT systems.
Active interface modules (AIM)
- The Active Interface Modules combine with the Active Line Modules to form a functional unit and are required for operation of the associated Active Line Module. The Active Interface Modules contain a Clean Power Filter and basic interference suppression to ensure compliance with Category C3 in accordance with EN 61800-3 with respect to emitted interference.
Controlled by the control unit, motor or power modules do the heavy lifting by getting the drive's AC power to the motor.
PM240-2 sets the 21st Century standard for efficiency and flexibility
Using the latest power component technology, the PM240-2 Power Modules offer many benefits not seen before in general purpose and high-performance single-asix variable frequency drives (VFDs).
The PM240‑2 Power Modules in blocksize format feature the following connections and interfaces as standard:
- Line supply connection
- PM-IF interface for connection of the PM240‑2 Power Module and CU310-2/SIMOTION D410-2 Control Unit or CUA31/CUA32 Control Unit Adapter. The PM240‑2 Power Module also supplies power to the CU310‑2/SIMOTION D410‑2 Control Unit or CUA31/CUA32 Control Unit Adapter by means of an integrated power supply
- Terminals DCP/R1 and R2 for connection of an external braking resistor
- Motor connection using screw terminals or screw studs
- Control circuit for the Safe Brake Relay for controlling a holding brake
- 2 PE/protective conductor connections
Power Modules without integrated line filter can be connected to grounded TN/TT systems and non-grounded IT systems. Power Modules with integrated line filter are suitable only for connection to TN systems with grounded neutral.
Push-through variant
The push-through variant allows the cooling fins of the Power Module to be pushed through the rear panel of the control cabinet. Push-through versions should be used in applications where the amount of power loss generated inside the control cabinet itself must be minimized.
The chassis format Power Module comprises a line rectifier, a DC link and a converter to supply the motor. Power Modules are designed for drives that are not capable of regenerating energy back to the power supply. Instead regenerative energy produced while braking is converted to heat using braking resistors.
The Motor Module comprises a self-commutated converter with IGBTs. It generates a variable voltage with variable frequency from the DC link voltage that feeds the connected motor. Multiple motor modules can be operated on a single DC link, permitting energy to be shared between motor modules. This means that if one module operating in generator mode produces energy, that energy can be used by another module operating in motor mode.
From installation to operation, redesigned for multi-axis efficiency
Recently-re-engineered C and D type motor modules offer significant advantages over other designs.
For a perfect fit:
- C type: Optimized for continuous load with up to 200 % overload (continuous motion)
- D type: Optimized for highly dynamic, intermittent duty cycles with up to 300 % overload (discontinuous motion)
The Motor Modules in booksize format C/D types have been developed to be fully compatible with the booksize series regarding spare parts and offer the following advantages:
- The portfolio is extended by single motor modules 18 A (C type), 24 A (C/D types) and 30 A (D type), as well as by a double motor module 18 A (D type).
- The width of motor modules 45 A and 60 A has been reduced from 150 mm to 100 mm, which makes a significant contribution toward saving space in the cabinet
- The amount of space required beneath the motor modules has been reduced via improvements in the design and a new motor plug connector
- With the new motor plug connector design, the brake conductors and the PE connection are integrated directly in the plug connector
- The motor connections on the double motor module are located side by side, resulting in a significantly improved level of accessibility
- Optimized shielding connection
- Optimized and ruggedized mounting plate
What happens when motors stop can be even more important than when they start. These devices ensure that the process is as efficient as possible.
Excess energy in the DC link is dissipated in the SINAMICS S120 blocksize braking resistor. The braking resistors are intended for use with PM240‑2 Power Modules which feature an integrated braking chopper, but cannot regenerate energy to the supply system.
The braking resistors for frame sizes A through C can be installed laterally next to the PM240‑2 Power Modules. For frame sizes FSD to FSF, they should be placed outside the control cabinet or outside the switchgear room so the heat is dissipated away from the power modules, reducing the amount of cooling required.
SINAMICS S120's Braking Module for the chassis format and the matching external Braking Resistor are required to bring drives to a controlled standstill in the event of a power failure (e.g. with an EMERGENCY STOP) or to limit the DC link voltage for brief periods of regenerative operation, e.g. if the Line Module is not capable of energy recovery.
The Braking module includes the power electronics and the associated control circuit. During operation, the DC link energy is converted to heat loss in an external braking resistor.
SINAMICS S120 booksize Braking Module and the matching external Braking Resistor are required to bring drives to a controlled standstill in the event of a power failure (e.g. emergency retraction or EMERGENCY STOP category 1) or limit the DC link voltage for brief periods of generator operation, e.g. when the regenerative feedback capability of the Line Module is deactivated. The Braking Module includes the power electronics and the associated control circuit. During operation, the DC link energy is converted into heat loss in an external braking resistor. Braking Modules function autonomously.
Braking Modules in booksize format can also be used for rapid discharge of the DC link
In this 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 uses the "push-through" 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 that emitted by the electronics. Degree of protection IP54 can be achieved at this "mechanical interface" – the external heat sink. 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 duct, which can also open outwards.
A liquid cooling system allows significantly more efficient heat dissipation so an air conditioning system is not required. With a low energy input for liquid cooling, significant energy savings can be achieved during operation. Further, there is the possibility of heat recovery. Compared to air cooling, the benefits provided by liquid cooling with a closed cooling circuit at high power ratings include a small footprint, reduced weight and low-noise converter operation. The maintenance expenditure required for the units is reduced through omission of filter mats. The coolant must be provided with the corresponding additives. It is thus advantageous to use the system especially in small and badly ventilated rooms and under harsh environment conditions prevailing, for example, on ships and in industrial environments.
A water cooling system for common circuits allows to use the water provided in the factory. This provides a common cooling circuit for the system, motor and drive. Only reduced requirements are placed regarding the water quality. No additives need to be added to the water circuit, which allows convenient and environment-friendly commissioning and maintenance. Further, the converter is resistent to oxygen entering the cooling water. The benefits provided by liquid cooling, for example, significant energy savings and efficient heat recovery, are also ensured for water cooling.
