Fundamentals ..................................................................................................................................

3
SINAMICS overview ......................................................................................................................... 9
Overview SINAMICS ........................................................................................................................ 10
The drives Family SINAMICS ........................................................................................................... 11
SINAMICS S120 overview ................................................................................................................ 12
Overview of components .................................................................................................................. 13
SINAMICS S120M ........................................................................................................................... 14
Communication among components ................................................................................................ 15
Overview of motors .......................................................................................................................... 16
STARTER engineering system ......................................................................................................... 17
Safety information for our course participants ................................................................................... 18
Exercise 1: Structure of the training equipment ................................................................................. 21

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Training Document 1-1 Fundamentals and overview
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Training Document 1-2 Fundamentals and overview
Automation The automation systems require various hardware and software components for
the machine control.

HMI The Human Machine Interface is used for the operator control and monitoring of
the machine. An HMI can consist of simple switches and lamps or a graphical
panel, part of a PC controller.

Controller The controller is the brain of the machine. Depending on the variant, it is
designated as programmable logic controller (PLC), motion controller or
industrial PC, and is responsible for open- and closed-loop control tasks in the
machine.

I/O Input and output signals (possibly distributed, this means physically separated
and connected via the bus system) and valve islands for the pneumatics.

Drives Drives are the mechanisms or processes with which an object is moved or its
movement created. This includes all types of actuators, e.g. motors and their
power units, pneumatic cylinders and their valve control, etc.

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Training Document 1-3 Fundamentals and overview
Controller The tasks of a programmable logic controller are the processing of I/O signals,
closed-loop control tasks and data processing.

Drive system The drive system should move a motor with a specified speed or to a defined
position. Various modules are required to do this: infeed, power units, motors,
encoders and a Control Unit.
The drive system can run independent of a higher-level controller. If a motion
control controller is deployed as higher-level controller, speed setpoints are
transferred to the various drives.
The Control Unit then uses an integrated speed and current controller to ensure
that the actual speed of the motor follows the transferred speed setpoint.

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Training Document 1-4 Fundamentals and overview
Converter A converter supplies a three-phase motor with a variable three-phase current.
For this purpose, the three-phase current from the supply system is rectified in
the converter and a three-phase current with variable frequency is created.

Frequencies Depending on the speed setpoint that is input, the converter outputs a frequency
of 0 to 50 Hz. Higher frequencies are also possible, depending on the motor.

Speed In some applications, a desired frequency is specified instead of the speed

setpoint. Based on the motor data, such as rated current, rated power and rated
speed, the converter knows which output frequency needs to be produced and
output to the motor.

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Training Document 1-5 Fundamentals and overview
Rectifier In a rectifier circuit, the three-phase current from the power supply is rectified.
The module for rectifying is also called the Infeed or Line Module.
Depending on the version, these modules can feed energy to the DC link or
from the DC link to the line.

DC link The DC voltage from the infeed is applied to the DC link, which is buffered using
capacitors. These capacitors are used to store the energy and are integrated
into the infeed and the inverter modules.

Inverter A power unit with transistors takes this DC voltage and generates a three-phase
current with a variable frequency and voltage from it.
The module is also referred to as a Motor Module.

Closed-loop control For open-loop and closed-loop control of these modules, a module is needed to
handle the application requirements and control and regulate the modules
accordingly.

Note The diagram above shows the principle of how a converter works. Today,
(almost) all converters for three-phase motors function according to this
principle. Additional components such as reactors, fuses, braking resistors, etc.,
are not shown.

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Training Document 1-6 Fundamentals and overview
Modular system In a modular drive system, several modules of one type can be used in the drive
system. For example, several inverters (Motor Modules) can be connected to a
DC link.

Energy exchange Energy exchange can relieve the strain on the infeed/regenerative feedback
unit; even then a diode rectifier may be sufficient.
Efficiency via the DC link connection is better than with energy exchange via the
supply system. In the latter case, the power unit of an infeed/regenerative
feedback unit would be involved in the process twice.

Retraction motion With machine tools and production machines, individual axes may need to be
retracted in order to protect tools or products in the event of a power failure.
Decelerating other drives (e.g. main spindle) means that energy is still available
for active motions.
The following must be taken into account:
• What is the most inefficient operating instance with the lowest kinetic
energy?
• The control electronics must still be supplied with power (differs according to
the converter type)

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Training Document 1-7 Fundamentals and overview
Control Unit The closed-loop and open-loop control unit is also referred to as the Control
Unit. It controls and regulates the drive modules with which it exchanges data
via a communication bus (DRIVE-CLiQ).
It is also the communication interface to the application. A speed setpoint, for
example is connected here via an analog input or a PROFIBUS network.
Line-side
components Line-side power components are fuses, contactors, reactors and filters, which
are required for switching the energy supply and meeting EMC requirements.
DC link
components DC link components are used optionally to stabilize the DC link voltage.

Motor-side
components Motor side (output side) components are motor reactors or sine filters, for
example.

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Training Document 1-8 Fundamentals and overview
Blocksize format Blocksize format units are optimized for single-axis applications and are
supplied only as Power Modules. The CU310 Control Unit can be snapped onto
them directly. The devices are cooled with an internal air cooling.
Booksize Compact
format Derived from the Booksize format, we have developed the Booksize Compact
format for machines that place particularly high requirements on the
compactness of their drives. The Booksize Compact format is thus particularly
suitable for integration into machines with high dynamic requirements and
confined installation conditions.

Booksize format Booksize format units are optimized for multi-axis applications and are mounted
adjacent to one another. The connection for the common DC link is an integral
feature.

Chassis format Higher-output units (approximately 100 kW and above) are constructed in
Chassis format. These are available as Line Modules, Power Modules and
Motor Modules. Chassis format units are cooled by an internal air cooling circuit
as standard. For special applications, e.g. for extrusion or marine applications,
liquid-cooled devices can be ordered.

Cabinet format Ready-to-use cabinet units are available for largest power ranges.

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Training Document 1-9 Fundamentals and overview
SINAMICS V These inverters focus on the essential issues, regarding both the hardware as
well as the functionality. This results in a high degree of robustness – and at the
same time low investment costs for the user.
Operation is directly at the inverter itself without having to use any additional
engineering tools. SINAMICS V are especially suitable for applications that do
not require any special drive know-how.

SINAMICS G In operation, SINAMICS G inverters fully utilize their technological strengths.

They are available from 0.37 kW up to 250 kW (0.5hp up to 400hp). Users
benefit from their standard and straightforward operating concept. This
minimizes training and service costs. And last but not least, SINAMICS G
inverters are attractive as a result of optimum price-performance ratio.

SINAMICS S SINAMICS S are predestined to address complex applications in plant and

machinery construction – as well as for the widest range of motion control tasks.
They set themselves apart as a result of an outstanding feature: the highest
degree of standard and integrated engineering.

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Training Document 1 - 10 Fundamentals and overview
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Training Document 1 - 11 Fundamentals and overview
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Training Document 1 - 12 Fundamentals and overview
AC/AC devices On AC/AC devices, the infeed and motor power supply functions are combined
in one device, the Power Module – available in Blocksize and Chassis formats.
For single-axis applications, drive control functions are performed by a special
Control Unit (CU310) mounted on the Power Module and for multi-axis
applications, by a Control Unit (e.g. CU320) connected by a DRIVE-CLiQ link. In
this case, a CU adapter is mounted on the Power Module in place of the Control
Unit.

DC/AC devices DC/AC devices (= Motor Modules) – available in Compact Booksize, Booksize
and Chassis formats – are characterized by their modular design.
SINAMICS S120 Cabinet Modules are components forming part of a modular
cabinet system for multi-motor drives with a central line infeed and a common
DC busbar of the type typically used in, for example, paper-making machines,
roller mills, test stands, or hoisting gear.
As standard, they are installed side by side in a row. Other installation types
(e.g. back-to-back) are possible on request.

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Training Document 1 - 13 Fundamentals and overview
CU320-2 For open- and closed-loop control of the drive units. A Control Unit CU320-2
can be used to couple up to several drives via Single and Double Motor
Modules. The number of drives is dependent on the mode.
CU310-2 CU310 Control Units are designed to control a single drive. They feature as
standard a PROFIBUS interface (CU310-2 DP) or a PROFINET interface
(CU310-2 PN) and a TTL/HTL or SSI encoder evaluation.
Line Module Line Modules generate a DC voltage from the line voltage and supply Motor
Modules with energy via the DC link. A distinction is made between the Basic,
Smart and Active Line Modules.
Motor Module Motor Modules are responsible for the power unit of the individual drives.
A distinction is made between
• Single Motor Modules for one drive
• Double Motor Modules for two drives
In principle, all Single and Double Motor Modules can be operated on Basic
Line Modules, Smart Line Modules or Active Line Modules for the appropriate
voltage range.
A wide range of single-axis and two-axis Motor Modules with graded current/
power ratings can be supplied.
DC link
components DC link components are available as Braking Modules, braking resistors,
Capacitor Modules and Control Supply Modules. The DC link components also
allow the implementation of multi-line constructions.
Electronic
components Further digital and analog inputs/outputs can be connected to the system using
the expansion components. Functions such as measuring probes or output
cams can be implemented.

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Training Document 1 - 14 Fundamentals and overview
S120M The S120M is a servo motor in the IP65 degree of protection with integrated
Power Module
- With/without holding brake
- Absolute encoder with 20-bit resolution per revolution or 12-bit multiturn
- The SINAMICS S120M is connected using a hybrid cable (power supply and
bus line for closed-loop control) to the Adapter Module 600 of the SINAMICS
S120 central drive system. The open- and closed-loop control of the S120M is
also made from the central drive system.

AM600 The Adapter Module 600 (AM600) is the interface between the central
SINAMICS (Booksize) components and the S120M integrated in the motor. The
AM600 is implemented in the Booksize Compact format with 75 mm module
width and opens a line of distributed S120M drives. Correspondingly, the DC-
link connections, the 24 V electronic power supply, the status LEDs, the DQ
sockets and the terminal strips are arranged and labeled similarly

Hybrid cable The pre-assembled hybrid cable already contains the signal and power cable in
a single cable. This reduces the time required for the wiring and for cutting
cables to length.
• Maximum permissible line length per Adapter Module 600: 100 m
• Segment length between an AM600 and the first node: ≥ 3 m ... ≤ 75 m
Segment length between two S120M: maximum 75 m
The complete cable length of the motor + hybrid cable depends on the central
power infeed (Line Modules)

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Training Document 1 - 15 Fundamentals and overview
Communication The communication between the Control Unit and the individual components of
the drive system is carried out via DRIVE-CLiQ, an Ethernet-based
communication protocol.

DRIVE-CLiQ The internal drive communication has the following properties and features:
• Connects all components including motors and encoders.
• Implements the connection of drive-related I/Os and encoder systems
integrated in the motor.
• Encoders in DRIVE-CLIQ motors are powered via a 24 V supply integrated
in the cable.
• Uniform design of cables and connectors reduces part diversity, storage
costs and commissioning work.

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Training Document 1 - 16 Fundamentals and overview
Motor spectrum Not only Siemens motors, but also third-party motors, can be connected to
SINAMICS.
SINAMICS S120 is optimized for the operation with Siemens motors.

Preferred motors for production machines:

• 1F synchronous servo motors
• 1PH asynchronous servo motors

Innovative machine solutions with

• 1FN linear motors
• 1FW torque motors (e.g. for extruders, rotary tables or servo presses)

Rating plate data With SINAMICS S120, it is also possible to use third-party motors. Only the
rating plate data needs to be entered for induction motors. The system can
determine the remaining data using stationary or rotating measurement.

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Training Document 1 - 17 Fundamentals and overview
SIZER This tool will support you during the technical configuration of the hardware and
software components required for automation including calculation of the load
machine.
The results can be exported in different formats for order processing or
documentation.
In a future version, the data of the STARTER service tool will also be supplied
with the information from the SIZER project.
For detailed specification of low-voltage standard motors, the SIZER can
incorporate the DT configurator.
Furthermore, the MOTOX gear designer can be used for standard gear motors.

STARTER The STARTER standalone tool is provided for easy, guided, graphics-oriented
start-up of the SINAMICS and MICROMASTER drive units; it is also integrated
in the SIMATIC Manager as part of DriveES Basic.
The tool also allows high-level expert access with comprehensive diagnostics
and trace functions.

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Training Document 1 - 18 Fundamentals and overview
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Training Document 1 - 19 Fundamentals and overview
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Training Document 1 - 20 Fundamentals and overview
Safety information Please note that:
• The course exercises have been produced for:
 A course held by the course leader
 Activities carried out on special training equipment
• The training equipment is operated under laboratory conditions.
In case of doubt, always ask your course leader – particularly when handling
components that carry electrical current or can move.
• When carrying out work on equipment, the safety information in the
associated product documentation must always be observed!
The Training Documents alone are not sufficient.

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Training Document 1 - 21 Fundamentals and overview
Task Familiarize yourself with your training equipment. Determine which components
of the SINAMICS S120 system are installed.

1. Enter the components determined for the SINAMCIS S120 converter system
above.
Order numbers are not necessary.

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Training Document 1 - 22 Fundamentals and overview
Task Determine which motors are installed.

1. Enter the data for the motors installed above.

Order numbers are not necessary.

2. Also clarify which encoder is installed.

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Training Document 1 - 23 Fundamentals and overview
Task Gain an overview of the electrical wiring.

1. Determine the most important connections:

• Where is the line infeed connected?
• Where are the motors connected?
• Where are the encoders connected?
• Where is the connection between CU 320-2 and Line Module?
• Where is the connection between CU 320-2 and Motor Module?
• Where is the switch box connected?

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Training Document 1 - 24 Fundamentals and overview