Siemens Motors

Drive & Motor
Workshop
Indonesia September 2012
© Siemens AG 2012. All Rights Reserved.

Drive & Motor Workshop
Principle of induction motors

Principle of variable speed drives
Sinamics V/G/S
Tools & Software
How to select and configure a drive
SINAMICS Portfolio Update
Migration to Sinamics
Electrical Servo Pump

Principle of low voltage motors
Electrical Energy Mechanical Energy
V = Voltage [V] T = Torque [Nm]

I = Current [A] n = Speed [1/s]
P = V * I = Power [W] P = T*2* *n = Power [W]
An low voltage motor converts electrical energy into

mechanical energy:
1 Ws = 1 Nm = 1Joule

Page 3 2012-09-28 Industry Sector / Drive Technologies
Mechanical design of a low voltage motor

Three Phase AC Voltage
A three phase AC voltage consists of three sinusoidal voltages

which are offset by 120° respectively.
The frequency is depending on the country 50 Hz or 60 Hz

Low voltage motor on a three phase AC supply
• An electric current flowing through a

conductor creates a magnetic field
• The three phase AC supply creates a
rotating magnetic field in the motor stator
•The magnetic field of the rotor is either
created by permanent magnets or by
induction
• The magnetic field of the rotor follows the
rotating magnetic field of the stator
•The rotating stator field together with the P[W ]
rotor field generate a torque (Torque = T [ Nm]
2 * * n[ 1 ]
Force of a rotational motion) s
• Torque = T [Nm]; Power = P [W]; Speed =
n [1/s] P[ kW ]
T [ Nm] 9550 *
n[rpm]


Sinamics V/G/S
Tools & Software

Low voltage motor on a three phase AC supply
3Ø AC Supply
Fixed Frequency = 50 Hz
The rotating magnetic field of the supply has a fixed

frequency, therefore the motor will run at one speed
only
Low Voltage Motor

Principle of a Variable Speed Drive
3Ø AC Supply
3Ø AC Voltage
Variable Frequency
i.e. -50 Hz to +50 Hz
Variable Speed Drive
The frequency must be varied to vary speed of AC

Motor
Low Voltage Motor

Components of a Variable Speed Drive
Rectifier DC Link Inverter
A rectifier is an electrical The DC Link is located An inverter is an electrical

device that converts between the rectifier on the device that converts direct
alternating current (AC), supply side and the inverter current (DC) to alternating
which periodically reverses on the motor side. The DC current (AC); the converted
direction, to direct current link usually consists of a AC can be at any required
(DC), which is in only one capacitor which stabilizes voltage and frequency with
direction, a process known the DC voltage and the use of appropriate
as rectification. decouples the rectifier from transformers, switching, and
the inverter. control circuits.

3Ø AC Supply
When we say “Variable Speed Drive” we also mean:

Variable Frequency Drive, Frequency Converter, Inverter, Drive,
VFD, VSD, etc.
Low Voltage Motor

3Ø AC Supply
A diode is a two-terminal
electronic component that
conducts electric current in only
one direction. In the other
direction a diode behaves like
an isolator. Low Voltage Motor

Rectifier diodes (3 Pair) mounted on the heat sink of a

90 kW drive

3Ø AC Supply
A capacitor (formerly
known as condenser) is
a device for storing
electric charge
(Energy).
Low Voltage Motor

DC Link capacitors of a 11 kW drive

DC Link Voltage
Supply Voltage Supply Current DC Link Voltage
Single
Phase
Supply Voltage Supply Current DC Link Voltage
Three
Phase

3Ø AC Supply
A transistor is a
semiconductor device used
to amplify and switch
electronic signals. Unlike
contactors, relays etc.
transistors switch without any Low Voltage Motor
mechanical movements.
Insulated Gate Bipolar Transistors Commutation (Flywheel) diodes

3Ø AC Supply

Capacitors
Low Voltage Motor

Pre Charging
Pre charge resistor Pre charge relay
When the inverter is first powered up, the capacitors are discharged
(at 0V DC) and therefore behave like a short circuit. A pre charge
circuit is used to reduce the current and avoid damage of the
rectifier diodes.

Braking Chopper & Resistor
Braking Resistor
(Commonly installed externally via
terminals)
Braking Chopper
Low Voltage Motor

IGBT Switching
Consider this top IGBT switching ‘on’…
…and this lower IGBT switching ‘on’

IGBT Switching - Commutation
The stored energy in the motor coil

maintains a current via the commutaion
diodes after the IGBT’s are switched off

Output Voltage
Voltage
The IGBT’s are switched on
for a certain amount of time
The width of the pulses varies in time to create a

RMS sinusoidal voltage.
This is called Pulse Width Modulation (PWM)
Current
0V
Time
The square wave voltage generates an approximately sinusoidal

current when connected to the inductive load of a low voltage
motor

Design of a Variable Speed Drive
3Ø AC Supply
Serial Communication
Input/Output
Interface
Digital In- / Outputs
ASIC Motor
Analog In- / Outputs
Microprocessor

Principle of a PM240 / PM340 & BLM - Motoring
3Ø AC Supply
Motoring Operation: Motor

•Current through the rectifier diodes into the DC link capacitors
•Through the IGBT‘s to the motor

Principle of a PM240 / PM340 & BLM - Generating
3Ø AC Supply
Generating Operation:
•Current from the motor through the flywheel diodes to the DC link capacitors Motor
•Voltage in the DC link capacitors increases
•At a preset limit of the DC link voltage the barking chopper starts pulsing
•The regenerated energy will be discharged through the braking resistor and turned
into heat

Principle of a PM250 - Motoring
3Ø AC Supply
Motoring Operation:
•Same like PM240 / PM340
Motor

Principle of a PM250 - Generating
3Ø AC Supply
•Current from the motor through the flywheel diodes to the DC link
Motor
•At a preset limit of the DC link voltage the rectifier IGBT’s start pulsing
with supply net frequency
•The energy will be regenerated to the supply net

Principle of a Smart Line Module - Motoring
3Ø AC Supply
Line Choke
Motoring Operation:
•Same like PM240 / PM340
Motor

Principle of a Smart Line Module - Generating
3Ø AC Supply
Line Choke
Motor
•At a preset limit of the DC link voltage the rectifier IGBT’s start a
controlled pulsing pattern
•The energy will be regenerated to the supply net

Principle of a Active Line Module - Motoring
3Ø AC Supply
Line Choke
Motoring Operation:
•Current through the controlled rectifier IGBT’s into
the DC link capacitors Motor

Principle of a Active Line Module - Generating
3Ø AC Supply
Line Choke
•DC link voltage stays on the predefined level Motor
•The regenerated energy of the motor will be regenerated to the supply
net via the controlled rectifier IGBT’s

SINAMICS S120 ALM – AFE Principle
Motoring Operation
- IGBT, diode and coil work as a
“Step-up Converter”
- DC Link Voltage > 1.42 x Supply Voltage
- It is possible to achieve an
approximately sinusoidal input current
with the correct switching pattern
Generating Operation
- IGBT, diode and coil work as
“Step-down Converter”

Overview Line Modules
Motoring Generating
Operation Operation
PM240/PM340 +
Basic Line Module
PM250 +
Smart Line Module
Active Line Module


Sinamics V/G/S
Tools & Software

SINAMICS Drive Family
High Performance Drive
SINAMICS S
General Performance Drive
SINAMICS G
Basic Performance Drive
SINAMICS V

SINAMICS V20 (From May 2013)
Power range: 0.12–15 kW

ECO mode on V/f, V2/f
Hibernation mode
Energy consumption display
Parameter loading without power supply
Application and connection macros
“Keep on running mode” for
uninterrupted operation
Wider voltage range, advanced cooling
design and coated PCB increase
robustness
USS and MODBUS on terminals
SINAMICS V20 – the cost-effective, reliable and

easy-to-use inverter for basic applications

SINAMICS V60
Complete solution:
SINAMICS V60 is designed for operation
with
1FL5 servomotors. SINAMICS V60 and
1FL5 motors,
together with the matching connection
system,
form a ready-to-run drive system.
Simple commissioning:
The drive solution is commissioned by
simply setting
parameters at the device. The motor data
are already
preset.
SINAMICS V60 – The perfect solution for basic servo applications

SINAMICS G110

Simple installation and mounting
Fast and straightforward commissioning
using an optional operator panel or
software engineering tool
For variable-speed drives (V/f) connected
to single-phase 200 V to 240 V line
supplies
Ideal for use with LOGO! and SIMATIC
S7-200 control systems
The versatile single-motor drive for

low power ratings
The compact variable frequency drive for centrifugal pumps, radial/axial fans and
compressors as well as conveyor belts, roller and chain conveyors with only three frame
sizes and freely parameterizable digital inputs offers the highest possible degree of flexibility.

SINAMICS G120P
USB interface, IOP operator unit

Energy-efficient through minimum apparent power
losses, automatic adaptation of the motor current to the
actual load relationships using the ECO mode
Automatic changeover to line operation at rated speed
Hibernation (sleep mode) depending on the setpoint,
auto-ramping function for current limiting
Communication: USS, Modbus RTU, BacNet MS/TP,
PROFIBUS DP, CANopen
The specialist for pumps, fans and compressors
The easy-to-use standard drive that is simple to commission is especially used in building
technology, the water industry and process industry for heating, ventilation and air-
conditioning.

SINAMICS G120C
Compact device
Highest power density of its class
Power range: 0.55–18.5 kW
Simple commissioning and maintenance
With BOP-2 or IOP operator panel
Safety Integrated: STO
Communication options: DP,
CANopen, USS, Modbus RTU
The compact, single-motor drive with small power rating and

suitable functionality
The rugged standard drive defines new standards in its class regarding small size, fast
commissioning times, extremely simple operator control, high degree of service-friendliness
and integrated functionality. For example, for belt conveyors, mixers, extruders, pumps, fans,
compressors and simple handling machines.

SINAMICS G120

Safety Integrated: STO, SS1, SLS and SBC
(without encoder) up to SIL2 according
to IEC 61508 and up to Category 3 according
to EN 954-1; in compliance with IEC 61800-5-2
Communication via PROFIBUS,
PROFINET, RS 485, USS, Modbus RTU, CANopen
Energy-efficient thanks to energy recovery
and low harmonics
Parameter copy function for series
Commissioning
The modular single-motor drive for small up to medium power ratings
The rugged standard drive for universal applications in the industrial environment can even
be used under extreme environmental conditions thanks to its clever cooling concept. Power
modules capable of energy recovery and Control Units can be freely combined.

SINAMICS G130 / G150
V/f control and vector control with or without

encoder
Power range from 75 up to 2700 kW
Simple commissioning and operator control
Available as standard cabinet or as
chassis modules
Service-friendly thanks to easily
accessible device modules
Communication via PROFIBUS, PROFINET
and other interfaces
Energy-efficient through variable-speed
operation
Safety Integrated
100% line supply voltage at the motor
without any secondary effects
When required, with integrated line harmonics
filter and dv/dt filter
The universal variable frequency drive for high-rating single-motor drives
The quiet and compact drive for single motor applications, which do not require energy recovery,
e.g. pumps, fans, compressors, extruders, mixers and crushers.

SINAMICS G110D
Continuous speed control of three phase

induction motors
Fulfills all of the requirements of conveyor- related
applications with frequency control
Distributed topology — ideal for applications
dispersed over wide areas
Integrated into TIA via AS-Interface
Wide power range from 0.75–7.5 kW
The distributed single-motor drive for basic solutions
This low-profile solution with degree of protection IP65 for basic drive tasks in conveyor
technology combines the Control Unit (CU) and Power Module (PM) function units.

SINAMICS G120D
Power range from 0.75–7.5 kW

High efficiency thanks to energy recovery and
low line harmonics
Safety Integrated: STO, SS1 and SLS
encoderless
Basic Positioning Function (EPOS)
Interchangeable memory card MMC
Communication via PROFIBUS, PROFINET,
PROFIsafe
Part of Totally Integrated Automation
The distributed single drive for high-performance solutions
The distributed, interchangeable variable frequency drive in a high degree of protection (IP65)
has a low profile, is compact and thanks to its metal housing, extremely rugged; ideal for
demanding conveyor-related applications in the industrial environment.

SINAMICS S110
Servo control
Power ratings from 0.12–90 kW
Safety Integrated
Integrated positioning functions
Simple system connection to higher level
controls (e.g. PLCs) with PROFIBUS,
PROFINET, CANopen
The specialist for basic positioning tasks
The AC/AC unit for basic positioning of single axes with synchronous or induction motors.

SINAMICS S120

Servo/vector control, V/f control
Integrated safety and positioning functions
Freely configurable logic and closed loop control
functions
Additional motion control functions in conjunction
with SIMOTION or SINUMERIK
High degree of scalability, flexibility, combinability
Energy-efficient as a result of energy recovery or
common DC link
PROFIBUS/PROFINET/CANopen interface
Different cooling types: air, liquid, cold plate cooling
The flexible, modular drive system for sophisticated tasks
The modular drive system in different formats for high-performance and motion control
applications in single- and multi axis configurations for synchronous and induction motors.

SINAMICS S120 AC/AC
Blocksize format (0.12–90 kW)

Chassis format (110–250 kW)
From 18.5 kW also in a liquid-cooled
version
Can be combined as required with other
size formats
SINAMICS S120 AC drives for high-performance single-axis

applications

SINAMICS S120 DC/AC
Booksize Compact format (0.9–9.7 kW)

Booksize format (1.6–107 kW)
Chassis format (75–1200 kW)
Also in a liquid-cooled version
Highly compact using double-axis modules
SINAMICS S120 Cabinet Modules as
preconfigured cabinet elements, specifically
for multi axis applications in plant
construction (power ratings up to 4500 kW)
SINAMICS S120 DC/AC units for high-performance multi-axis

applications

Sinamics S120 – Scalability through modularity
Example: Configuration of HMI PLC

a multi axis drive based on
Sinamics S120 Booksize
units
(Profidrive)
DRIVE-CLiQ
Motor Module
Motor Module
Motor Module
Motor Module
Line Module
CU320
SMC10/ SMC30
SMC20
TM31
Motor with Motor without

Digital-/Analog I/O DRIVE-CLiQ- DRIVE-CLiQ- DRIVE-CLiQ- Encoder
Interface Interface Encoder
© Siemens AG 2012. All(TTL/HTL)
Rights Reserved.
SINAMICS S150 Cabinet Units
4Q operation with energy recovery as standard

Power range: 75–1200 kW
Significant energy saving, especially for
frequent braking cycles
V/f control and vector control with or
without encoder
Rugged with respect to line voltage fluctuations,
reactive power can be compensated
Communication via PROFIBUS, PROFINET as
well as additional interfaces
Integrated safety functions
The drive solution for sophisticated high-rating single-motor drives
The ready-to-connect drive cabinet for applications requiring energy recovery, e.g. test stands,
elevators, cranes, conveyor belts, presses, cable winches, centrifuges, crosscutters and
shears.

SINAMICS DCM
Highest degree of scalability by being able

to select between a Standard Control Unit
and an Advanced Control Unit or a
combination of both
Power range: 6 kW–30 MW
Maximum degree of flexibility for specific
plant and system requirements
Compatible to the predecessor product
High plant availability through maximum
reliability, service-friendly design and
redundant concepts
Simple and fast commissioning
Communication via PROFIBUS, optionally
PROFINET
As ready-to-connect drive unit or Control
Modules for retrofit projects
The scalable DC drive for basic and demanding applications
Suitable for DC applications in all sectors, for instance, rolling mills, wire-drawing machines,
extruders and kneaders, cable railways and elevators as well as test stands.

Internet Link DT Infocenter
http://www.siemens.com/drives

Internet Link for further information
http://support.automation.siemens.com

DT- Configurator
http://www.siemens.com/dt-configurator
The DT Configurator supports you with:

Selecting the drive based on the
application
The subsequent ordering process
DT Configurator supplies you with:

A drive that is optimally tailored
to your requirements
2D/3D models
Operating instructions
Data sheets
Simple entry using the DT Configurator


Sinamics V/G/S
Tools & Software

SIZER engineering software
SIZER supports you when:

Defining the mechanical system
Dimensioning the drive, motor and gear unit
Configuring additional system components
Configuring the open-loop/closed-loop control
SIZER supplies you with:

Engineering results: characteristics, technical
data, layout drawings and dimension drawings
Calculation of the load-dependent energy
demand
Calculation of the performance
Calculation of the harmonics
Part lists with the associated ordering data
Engineering with SIZER ...

SINAMICS sets itself apart as a result of its standard engineering. Once you know one
variable frequency drive, then you know them all. This makes it easier for you, especially
when it comes to implementing complex plants and systems with several drives – or
subsequently expanding them. SIZER is available to help engineer all of the drives in the
same standard fashion.

STARTER commissioning software
STARTER supports you during:

parameterization
commissioning
diagnosis,
Service
STARTER supplies you with:

Simple and efficient parameterization through
- rapid commissioning with few parameters
- expert mode with all parameters
Support of service and diagnostic functions
directly at the device or via Teleservice access
... commissioning drives with STARTER

STARTER is an intelligent tool that can be used for all SINAMICS drives. It allows you to
simply configure and commission the drive components. More specifically, STARTER is
menu-prompted and graphically supported.


Sinamics V/G/S
Tools & Software

CORRECT MOTOR & DRIVE SELECTION – Load Considerations
What type of application do we have?

How is the load cycle?

CORRECT MOTOR & DRIVE SELECTION – Supply Data
For a correct motor and drive selection the supply voltage is very
important. The supply voltage determines the “Field Weakening
Point” which is a crucial information.
Field Weakening Point
The supply frequency is not so important when using drives

because it will be rectified to a DC voltage anyway.
CORRECT MOTOR & DRIVE SELECTION – Motor Limitations
Additionally certain motor limitations need to be considered:
Torque reduction at low speeds and above the Field Weakening Point

Loads Cycle Times
1 cycle time
T 20 Nm
RMS torque: 12Nm
5 Nm
0 Nm
5s 5s 7s 10s time
-15 Nm
Many loads (like elevators, hoists and cranes) have a certain load
duty cycle.

The optimal starting point would be a customer who can provide

a speed/torque diagram as well as the load duty cycle.
Unfortunately that is a very rare case.
Speed/Torque Curve of a certain Load

CORRECT MOTOR & DRIVE SELECTION – Network Configuration
Different Network Types
TN Network TT Network IT Network

• Most common network for • The drive may interfere with • No EMC filter allowed
drives the ELCB
• Order drive w/o EMC filter
• No special measures • Special ELCB type necessary
necessary • Remove Y-Capacitor (in MM4)

Options: Line Filter acc. EMC directive IEC61800-3
EMC directive: “The capability of a device to work in the

electromagnetic environment without itself causing electromagnetic
interferences which are unacceptable for other devices in this
environment”
=> A EMC Filter protects other devices from interference send out by
the inverter!
Locations for the installation of drive systems are divided into two
different environments:
The first environment comprises living accommodation or locations

where the drive system is directly connected to the public network
without intermediate transformer.
The second environment is understood to be all locations outside

living areas. These are basically industrial areas which are powered
from the medium-voltage network via their own transformers.

Options: Line Filter acc. EMC directive IEC61800-3
Without Filter: Only for Category C3 second environment.
Filter Class A: Use for Category C2 second environment.
Filter Class B: Use for Category C1 and C2 first environment.

Options: Line Choke / Line Reactor
Line Chokes have three main purposes:
1: Inductance for commutation (Reduction of current peaks)
2: Reduction of harmonics
3: Protection against voltage peaks
When is it necessary to use a line choke?
- If the ratio: Supply line short circuit power > 100 x rated drive power
(System impedance / Fault Level < 1%)
a line choke is necessary to reduce current peaks.
- If the customer want to reduce the harmonics.
- If the customer want to protect the drive against external voltage peaks.
If in doubt it is always better to use a line choke!

Calculate the System / Transformer Short Circuit
Impedance
Q: What is the impedance of a transformer?

A: The percentage of the voltage you need to apply to the input of a
transformer to have rated current flowing while the transformer output is
in short circuit.
I Short Circuit
Vsc
Vsc imp 100 %
V
imp = Impedance [%]
Vsc = Short Circuit Voltage [V]
V= Rated Voltage [V]
Isc = Short Circuit Current [A]
I = Rated Current [A]

Calculate the System / Transformer Short Circuit
Impedance
Normally the impedance of a transformer is given on the nameplate.
Then the Short Circuit Power (Fault Level) can be calculated as:
100 %
Psc PR impT = Impedance Transformer [%]
imp T impS = Impedance System [%]
PR = Rated Power [VA]
Psc = Short Circuit Power [VA]
Then the System Impedance is: PRD = Rated Drive Power [VA]
100 %
imp S * PRD
PSC
Options: Line Choke – AC Choke vs DC Choke
Siemens is using pure AC choke solutions. Some competitors use DC

chokes. To convince the customer we need to point out the
disadvantages of the DC choke:
1: The harmonic reduction for AC and DC chokes is almost the same.

-> no advantage or disadvantage here.
2: A DC choke is smaller and lighter than a AC choke and usually build in.
-> Advantage for DC choke.
3: A DC choke cannot protect the drive against voltage peaks.

-> Disadvantage for the DC choke.
4: The current in a DC choke flows only in one direction. This leads to changes
in the choke characteristic which also changes the harmonics.
5: In some cases the input current between the 3 phases is imbalanced. A AC

choke can reduce this imbalance, a DC choke cannot.

Options: Output Reactor / dV/dt Filter / Sinewave
Filter
The difference between output choke, dV/dt filter and sinewave filter is shown here:

Options: Output Reactor / dV/dt Filter / Sinewave
Filter
Line Chokes, dV/dt Filters and Sinewave Filters are used when:
1: The isolation of the motor windings is not good or it is not known.
2: The cable length between drive and motor is very long
If in doubt it is always better to use a output choke!

Output Derating
Derating of the drive output means a reduction of the permitted

output power.
This can be necessary because of three reasons:
1: High Pulse Frequency
- Higher pulse frequency creates higher internal
losses (internal heat loss increases)
2: High Ambient Temperature
- High ambient temperature reduces the cooling effect
3: High Installation Altitude
- In high altitudes the air is thinner which also
a) reduces the cooling effect
b) has less isolating effect
In terms of derating Siemens drives are mainly better than most

competitors drives!

Output Derating – High Pulse Frequency (PM240)

Output Derating – High Ambient Temperature

Output Derating – Installation Altitude & Voltage

Overload Capability
The overload capability of a drive is divided into two

categories:
HO = High Overload = CT = Constant Torque = Rated Output for MM440
LO = Light Overload = VT = Varable Torque = Rated Output for SINAMICS G120
Originally the rated output of Siemens drives was always the HO / CT rating.
The competition usually took the LO / VT rating as rated output.
To make it easier to compare Siemens also took the LO / VT rating as rated

output for SINAMICS G120
The overload capability of Siemens drives is mainly

better than the competitors drives!
Overload Capability
I [A]
3 sec
200 % HO
150 % LO
150 % HO
110 % LO
100 %
60 sec
300 sec
t [s]
HO: high overload: 1.5 In during 57 sec in 300 sec
2 x In during 3 sec in 300 sec
LO: light overload: 1.1 In during 57 sec in 300 sec
1.5 x In during 3 sec in 300 sec

What are Harmonics?
1
All periodic signals can be
0.5
represented as a sum of sine-
0 functions with periods equal to
integer numbers of the fundamental
-0.5
component
-1
0
1 2 3 4 5 6 7
f (t ) ah sin( h 1t )
1
0.5
Harmonics is decomposition of a
0
signal into different (integer of
-0.5 fundamental) frequencies
-1
0
1 2 3 4 5 6 7

What causes Harmonic Distortion?
What causes Harmonic Distortion?
Any non linear effects in the Power System may cause system
harmonics distortion.
- Saturation of transformers or magnetic equipment.

- Rectifier loads (drives, computer power supplies etc.)
- Phase controlled loads (e.g. DC Drives)
- Resonant systems such as RF heaters.
AC Drives are usually rectifier fed, and therefore can cause

system harmonics

Problems caused by Harmonics
What problems do Harmonics cause?
- Overheating of transformers and cables

- Excess neutral currents in buildings
- Spurious tripping of equipment
- Reduced lifetime of connected products
- Problems with lighting systems
- Limits on capacity of standby generators and UPS systems
Therefore there is increasing concern and legislation relating

to harmonics

Typical Harmonics
This supply shows typical

distortion caused by a DC
Drive (controlled rectifier)
Typical distortion caused

by a 6 pulse rectifier like it
is used in almost all
drives

Voltage and Current Harmonics
Non-linear
Non-linearLoad
Load
System
Current
CurrentDistortion
Distortion Voltage
VoltageDistortion
Distortion
Impedance
Contribution
Contributionto
to Disturbance
Disturbancetoto
system
systemlosses
losses other
otherusers
users
Current distortion appears on equipment level

Voltage distortion appears on system level

Voltage and Current Harmonics
Required knowledge to calculate voltage distortion:

- The harmonic currents of the non-linear load
- The system short-circuit impedance.
It is NOT possible to predict the voltage

distortion knowing only the drive’s performance.
Voltage distortion is a SYSTEM performance

parameter
Current distortion relates to the individual drive

and equipment

Conventional Harmonic Reduction Techniques
///
///
/// /// ///
///
AC-Reactors Multi-Pulse Passive Filters
/// /// ///
Small DC-Link
DC-Chokes Capacitors Active Filters

Innovative Siemens Solution: Active Line Module
Energy regeneration
back to the supply net
No braking resistors etc.

necessary
Step up DC link voltage -

> Output voltage
remains constant during
supply fluctuations
Power factor = 1
Harmonic distortion
almost 0%


Sinamics V/G/S
Tools & Software

4 power modules cover the different market
requirements
Overview of power modules

Efficient infeed
stronger DC- Less harmonics
Link smaller DC-Link
Chopper
Higher dynamic
PM250
PM240-2
PM240 FSA
IP55 IP20 Energy regeneration
Ideal for
PM230 applications with
No chopper integrated braking high regenerative
chopper energy
Only for non dynamic
applications, such as Ideal for Reduction of energy
pumps, fans, compr. applications with costs in total system
low regenerative context
low harmonics energy
IP 55 / IP 20

The PM240-2 will join PM240 and PM340 into one
product line
PM240-2
PM240
Released with CU2xx
Works with CU2xx and CU3xx
Based on new platform (High power
General
density, slim design, incl. push
Blocksize Power Module through)
FS A ( 3kW) to be released soon

3AC 400V FS B+C planned
FS D-F planned
Combined 1AC and 3AC units planned

1/3AC
Development in parallel with 3AC400V
200V
PM340 types
Released with CU3xx

G120 – differentiation of Control Units
Overview of G120 Control Units
CU250S-2*
CU230P-2 Extended I/O
configuration
CU240E-2 Special I/O Closed loop
configuration for control
CU240B-2 HVAC-app‘s EPos
Standard I/O
(i.e. 230V Relais, Optional Servo
configuration
Ni1000, ...) control
STO as Standard
Basic I/O Real time clock Various encoder
Additional Safety
configuration USS, BACnet types
functions optional
USS or DP MS/TP, ModBus, Extended Safety
USS or DP
CANopen or DP USS, DP or PN
* Sales release of CU250S-2 expected in May 2013


Sinamics V/G/S
Tools & Software

Migration of Micromaster to SINAMICS
Migration of MM4 to Sinamics

Original Drive G110 MM410 MM420 MM430 MM440
Performance standard encoder

New drive V20 V20 G120 G120P G120 G120
New drive PM PM230 PM230 PM240 PM240
New drive CU CU240B CU230P CU240E CU250S
* Sales release of Sinamics V20 and CU250S-2 expected in May 2013

Migration of Masterdrive to SINAMICS
Migration of Masterdrive to Sinamics

Original Drive MD VC MD MC
No. of axis single multi single multi

Performance standard high high standard medium high high
New drive G120 S120 S120 G120 S110 S120 S120
New drive PM PM240 PM340 DC/AC PM240 PM340 PM340 DC/AC
CU250S
New drive CU CU250S CU310 CU320 + License CU305 CU310 CU320


Sinamics V/G/S
Tools & Software

Conventional Power Pack vs. Servo Pump System
Constant pump Adjustable speed motor and

Controlled via valve / throttle constant pump
s s The expensive
proportional valve can
p P
U
Machine p P
U
be changed to a cheaper
directional valve
Q-Proportional Q-Proportional-
Directional Directional
Q valve
valve valve
valve
vQ v vQ v
T T
P P
p P
U
p PU
Pump
vP P
P
Asynchronous motor vP Q
Q Pump Servo motor
Pump Gear pump
The hydraulic system must be changed – the pump remains the same

Comparison conventional hydraulic &
Servo pump with energy saving components
Volume control via throttle valve Volume control via speed control
supply power supply power
200% efficiency factor: 130% efficiency factor:

transformer transformer
T T
199% 129%
M ~
motor ~ inverter
187% M
124% FU
pump M
motor
158% P
117% M
X throttle-valve
pump
100% V 100% P
Significant increase of efficiency from 50% up to 70% achievable.

Control via analog signals
control unit
Vset P set
0...10 V 0 ...10V
TM 31
Pact
U
0... 10 V p
P
T
SINAMICS S120 CU310-2

Easy implementation
control unit
V set
Profixxx
P set
SINAMICS S120
Pact
U
0...10V p
P
T
CU 3x0
Control via Standard- Bus system (Profibus, Profinet, CAN) / Analog 0-10VDC, 4-20mA

Realization with SINAMICS S120
Controller CU 310
Characteristic
P [bar ] nsoll
Set point
Communication
BUS
V soll P soll
Pressure- and
Characteristic Volume control
P ist n gesamt
V [mm /s]
Set point Psoll
DCC
Psoll
Actual pressure Scaling
10V = xx [bar]
*Drive Control Chart
Functions to control the Servo pump by DCC*- Modules

DCC solution
Prinzipschaltbild
Normierung
Qsoll
Normierung PID- Druck Kennlinie- Pumpe

Psoll
Nsoll
zum Motor
Normierung
Pist
D- Druck
Easy to adapt to additional requirements

Other pumps are possible but require calibration
Highlights Servo Pump System
Energy efficiency Know-how Software Hardware
Energy saving up 30% - 70% „Hydraulic-Know-how“ One software concept for all One hardware concept
compared to conventional can still be used power ranges for all power ranges of
hydraulic solutions SINAMICS S120
Control characteristics like a
Increase of production full electric machine Smaller components
Less oil wear, in regards to One product servo electric Less noise compared to
less oil wastage hydraulic unit to replace a variable pump / control valve
„conventional“ system
Less oil volume needed at Pump without gear
hydraulic reservoir, less Parallel operation of Reduction of mechanic
energy consumption during Servo pumps components and costs
oil heating
The process is less

dependent in relation to the
oil temperature
No pressure accumulator
needed
Energy saving of up to 70%

ROI 1 to 2 Years depending on requirement of machine type
Dimensioning
Power (kW) 10 20 30 60
Flow rate (L/min) 50 100 150 250

Maximal Pump Pressure (bar) 220 220 200 200
Pump IPVP IPVP IPVP IPVP

4-16 5-40 5-64 6-125
Motor 1FK 1FT 1PH 1PH
Drive PM340 PM340 PM340 PM340
25 A 75 A 90 A 145 A
Offer number A10746-2_11 Item. 01 Item. 02 Item. 03 Item. 04
Complete packages
Only one order number
Example
Energy saving e.g. 60t Injection Molding Machine
Energy consumption Asynchronous motor with constant speed
pump
Apparent power S = 16,97 kVA

Real power P = 15,18 KW
Idle power Q = 9,13 kvar
Energy consumption Servo motor with constant speed pump
Apparent power S = 6,54 kVA

Real power P = 5,38 KW
Idle power Q = 0,05 kvar
Oil temperature without Cooling: 42°C
250 Working days

6000 Machine working h/Year
15,18 kWh before
5,38 kWh after/ actual
0,12 € Energy cost
€ 10.929,6 before / Year
€ 3.873,6 actual / Year
Ratio
66% € 7.056
Energy / Year
saving

Thank you for your attention!
Ralf Schumacher
Siemens Pte Ltd
I DT MC
60 MacPherson Road
Singapore 348615
E-Mail: ralf.schumacher@siemens.com

Siemens Motors

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Drive & Motor

© Siemens AG 2012. All Rights Reserved.

Principle of induction motors

© Siemens AG 2012. All Rights Reserved.

Electrical Energy Mechanical Energy

V = Voltage [V] T = Torque [Nm]

An low voltage motor converts electrical energy into

© Siemens AG 2012. All Rights Reserved.

© Siemens AG 2012. All Rights Reserved.

A three phase AC voltage consists of three sinusoidal voltages

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• An electric current flowing through a

© Siemens AG 2012. All Rights Reserved.

Principle of induction motors

© Siemens AG 2012. All Rights Reserved.

The rotating magnetic field of the supply has a fixed

Low Voltage Motor

© Siemens AG 2012. All Rights Reserved.

The frequency must be varied to vary speed of AC

Low Voltage Motor

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Rectifier DC Link Inverter

A rectifier is an electrical The DC Link is located An inverter is an electrical

© Siemens AG 2012. All Rights Reserved.

Rectifier DC Link Inverter

When we say “Variable Speed Drive” we also mean:

Low Voltage Motor

© Siemens AG 2012. All Rights Reserved.

Rectifier DC Link Inverter

© Siemens AG 2012. All Rights Reserved.

Rectifier diodes (3 Pair) mounted on the heat sink of a

© Siemens AG 2012. All Rights Reserved.

Rectifier DC Link Inverter

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DC Link capacitors of a 11 kW drive

© Siemens AG 2012. All Rights Reserved.

Supply Voltage Supply Current DC Link Voltage

Supply Voltage Supply Current DC Link Voltage

© Siemens AG 2012. All Rights Reserved.

Rectifier DC Link Inverter

Insulated Gate Bipolar Transistors Commutation (Flywheel) diodes

Rectifier DC Link Inverter

Low Voltage Motor

© Siemens AG 2012. All Rights Reserved.

Pre charge resistor Pre charge relay

© Siemens AG 2012. All Rights Reserved.

© Siemens AG 2012. All Rights Reserved.

Consider this top IGBT switching ‘on’…

…and this lower IGBT switching ‘on’

© Siemens AG 2012. All Rights Reserved.

The stored energy in the motor coil

© Siemens AG 2012. All Rights Reserved.

The width of the pulses varies in time to create a

The square wave voltage generates an approximately sinusoidal

© Siemens AG 2012. All Rights Reserved.

© Siemens AG 2012. All Rights Reserved.

Motoring Operation: Motor

© Siemens AG 2012. All Rights Reserved.

© Siemens AG 2012. All Rights Reserved.

© Siemens AG 2012. All Rights Reserved.

© Siemens AG 2012. All Rights Reserved.

© Siemens AG 2012. All Rights Reserved.

© Siemens AG 2012. All Rights Reserved.