Liquid-cooled units

To comply with high requirements regarding installation and ambient conditions, SINAMICS S120 Cabinet Modules are also available in a liquid-cooled version.

The power loss of the units is transferred to the cooling liquid and dissipated, without noticeably increasing the temperature of the surrounding environment. As a consequence it is possible to save the expense of controlling the climate of the electrical room.

The system consists of liquid-cooled Basic Line Connection Module, Active Line Connection Modules, Motor Modules and a suitably selected cooling unit (Heat Exchanger Module).

Basic Line Connection Modules

Basic Line Connection Modules comprise a Line Connection Module and a liquid-cooled Basic Line Module. Basic Line Connection Modules are only suitable for infeed operation, i.e. they are not capable of feeding regenerative energy back into the supply system.

If regenerative energy is produced, e.g. when the drives brake, it must be converted into heat in external braking resistors using a supplementary Motor Module, which is used as Braking Module.

When a Basic Line Connection Module is used as the infeed, a line reactor appropriate for the supply conditions must be installed. If the infeed is realized via a transformer with an appropriate rating in 6-pulse operation with a Basic Line Connection Module or in 12-pulse operation with two Basic Line Connection Modules, the line reactor is optional and can be omitted.

If two or more Basic Line Connection Modules are operated in parallel on a common supply system in order to increase power, then line reactors must also be used.

Basic Line Connection Module ≤ 800 A

Basic Line Connection Module > 800 A

Active Line Connection Modules

Active Line Connection Modules comprise a Line Connection Module, a liquid-cooled Active Interface Module and a liquid-cooled Active Line Module. Active Line Connection Modules can supply energy to the DC link and return regenerative energy to the line supply (energy recovery). The use of an additional Motor Module as a Braking Module is only required if the drives need to be decelerated in a controlled manner after a power failure (i.e. when energy cannot be fed back into the line supply).

In contrast to Basic Line Connection Modules, Active Line Connection Modules generate a regulated DC voltage which remains constant irrespective of fluctuations in the line voltage. However, in this case, the line voltage must remain within the permissible tolerance range. Active Line Connection Modules draw a virtually sinusoidal current from the supply which limits any damaging current harmonics.

Active Line Connection Modules always contain an Active Interface Module, which in addition to a Clean Power Filter, also includes the necessary precharging circuit for the Active Line Module.

Active Line Connection Module with Active Interface Module and Active Line Module ≤800 A

Active Line Connection Module with Active Interface Module and Active Line Module >800 A

Motor Modules

Each Cabinet Module is fitted with one SINAMICS S120 Motor Module in chassis format and covers the power range from 315 kW to 1500 kW (380 V to 480 V or 500 V to 690 V). The power rating can be extended up to approx. 5700 kW by connection in parallel.

The Motor Modules can also be used as Braking Modules (braking chopper) if a 3-phase braking resistor is connected instead of a motor.
For more detailed information on this topic, please refer to the SINAMICS Low Voltage Engineering Manual.

Характеристика

Derating

Liquid-cooled SINAMICS S120 Cabinet Modules are rated for an ambient temperature of 45 °C and installation altitudes up to 2000 m above sea level and a plant-side raw water temperature of 38 °C (<IP55) or 33 °C (IP55). At ambient temperatures > 45 °C and a plant-side raw water temperature > 38 °C (<IP55) or 33 °C (IP55), the output current must be reduced. Ambient temperatures above 50 °C are not permissible. At installation altitudes > 2000 m above sea level, it must be taken into account that the air pressure, and therefore air density, decreases as the height increases. As a consequence, the cooling efficiency and the insulation capacity of the air also decrease.

The intake temperatures in the plant/system side raw water circuit must always be at least 7 K below the intake temperatures in the converter-side deionized water circuit. This ensures that the cooling power of the Heat Exchanger Module of the deionized water circuit, specified in the technical data, can be dissipated to the raw water circuit.

For additional information, please refer to the SINAMICS Low Voltage Engineering Manual.

Current derating as a function of the temperature of the cooling liquid in the converter-side deionized water circuit ¹⁾

Current derating as a function of ambient temperature¹⁾

¹⁾ The factors of the two derating curves must not be multiplied. The highest value in each case must be assumed for the purposes of calculation, so that the derating factor in the worst-case scenario is 0.9.

Permissible ambient temperature as a function of installation altitude

Voltage derating as a function of installation altitude

Current derating depending on the pulse frequency

To reduce motor noise or to increase output frequency, the pulse frequency can be increased relative to the factory setting (1.25 kHz or 2 kHz). When the pulse frequency is increased, the derating factor of the output current must be taken into account. This derating factor must be applied to the currents specified in the technical data.

For additional information, please refer to the SINAMICS Low Voltage Engineering Manual.

The following table lists the rated output currents of the Motor Modules with pulse frequency set at the factory as well as the current derating factors (permissible output currents referred to the rated output current) for higher pulse frequencies.

Derating factor of the output current as a function of the pulse frequency for units with a rated pulse frequency of 2 kHz

Motor Module	Type rating at 400 V	Output current at 2 kHz	Derating factor at pulse frequency
6SL3725-...	kW	A	2.5 kHz	4 kHz	5 kHz	7.5 kHz	8 kHz
380 ... 480 V 3 AC / 510 ... 720 V DC
1TE41-4AS3	800	1330	88 %	55 %	–	–	–

Derating factor of the output current as a function of the pulse frequency for units with a rated pulse frequency of 1.25 kHz

Motor Module	Type rating at 400 V or 690 V	Output current at 1.25 kHz	Derating factor at pulse frequency
6SL3725-...	kW	A	2 kHz	2.5 kHz	4 kHz	5 kHz	7.5 kHz
380 ... 480 V 3 AC / 510 ... 720 V DC
1TE36-1AA3	315	605	83 %	72 %	64 %	60 %	40 %
1TE37-5AA3	400	745	83 %	72 %	64 %	60 %	40 %
1TE38-4AA3	450	840	87 %	79 %	64 %	60 %	40 %
1TE41-0AA3	560	985	92 %	87 %	70 %	60 %	50 %
1TE41-2AA3	710	1260	92 %	87 %	70 %	60 %	50 %
1TE41-4AA3	800	1405	97 %	95 %	74 %	60 %	50 %
500 ... 690 V 3 AC / 675 ... 1035 V DC
1TG35-8AA3	560	575	91 %	85 %	64 %	50 %	35 %
1TG37-4AA3	710	735	84 %	74 %	53 %	40 %	25 %
1TG38-0AA3	800 ¹⁾	810	82 %	71 %	52 %	40 %	25 %
1TG38-1AA3	800	810	97 %	95 %	71 %	55 %	35 %
1TG41-0AA3	1000	1025	91 %	86 %	64 %	50 %	30 %
1TG41-3AA3	1200	1270	87 %	79 %	55 %	40 %	25 %
1TG41-6AA3	1500	1560	87 %	79 %	55 %	40 %	25 %

¹⁾ The Motor Module 6SL3725-1TG38-0AA3 is optimized for low overload; with an increased pulse frequency, the derating factor is higher than for the Motor Module 6SL3725-1TG38-1AA3.

The following tables list the maximum achievable output frequency as a function of the pulse frequency:

Maximum output frequencies achieved by increasing the pulse frequency in Vector mode

Pulse frequency	Max. achievable output frequency
1.25 kHz	100 Hz
2 kHz	160 Hz
2.5 kHz	200 Hz
4 kHz	320 Hz
5 kHz	400 Hz

Maximum output frequencies achieved by increasing the pulse frequency in Servo mode

Pulse frequency	Max. achievable output frequency
2 kHz	300 Hz
4 kHz	300/550 Hz ¹⁾

¹⁾ Higher frequencies on request.

Overload capability

SINAMICS S120 Cabinet Modules have an overload reserve, e.g. to handle breakaway torques. If larger surge loads occur, this must be taken into account when configuring. For drives with overload requirements, the appropriate base load current must, therefore, be used as a basis for the required load.

Permissible overload assumes that the drive converter is operated at its base-load current before and after the overload occurs, based on a duty cycle duration of 300 s.

For temporary, periodic duty cycles with high variations of load within the duty cycle, the relevant sections of the SINAMICS Low Voltage Engineering Manual must be observed.

Motor Modules

Motor Modules can be configured on the basis of different base load currents.

The base-load current for a low overload I_L is the basis for a duty cycle of 110 % for 60 s or 150 % for 10 s.

Low overload

The base-load current I_H for a high overload is based on a load cycle of 150 % for 60 s or 160 % for 10 s.

High overload

Basic Line Connection Modules and Active Line Connection Modules

The base-load current for a high overload I_{H DC} is the basis for a duty cycle of 150 % for 60 s or I_{max DC} for 5 s.

High overload

Технические данные

General technical specifications

Electrical specifications
Line voltages	380 ... 480 V 3 AC, ±10 % (-15 % <1 min) 500 … 690 V 3 AC, ±10 % (-15 % <1 min)
Line supply types	Grounded TN/TT systems and non-grounded IT systems
Line frequency	47 ... 63 Hz
Output frequency ¹⁾
Control type Servo	0 ... 550 Hz
Control type Vector	0 ... 550 Hz
Control mode V/f	0 ... 550 Hz
Line power factor Fundamental
Basic Line Module	>0.96
Active Line Module	Adjustable (factory-set to cos φ = 1)
Efficiency
Basic Line Module	>99 %
Active Line Module	>97.5 % (including Active Interface Module)
Motor Module	>98.5 %
Overvoltage category	III to EN 61800‑5‑1
Control method	Vector/Servo control with and without encoder or V/f control
Fixed speeds	15 fixed speeds plus 1 minimum speed, parameterizable (in the default setting, 3 fixed setpoints plus 1 minimum speed are selectable using terminal block/PROFIBUS/PROFINET)
Skippable speed ranges	4, parameterizable
Setpoint resolution	0.001 rpm digital (14 bits + sign) 12 bits analog
Braking operation	With Active Line Modules, four-quadrant operation as standard (energy recovery). With Basic Line Modules, two-quadrant operation as standard, braking by means of a Motor Module.
Cabinet system
Cabinet system	Rittal TS 8, doors with double-barb lock, base plate with cable entry options
Paint finish	RAL 7035 (indoor requirements)
Mechanical specifications
Degree of protection	IP21 (higher degrees of protection up to IP55 optional)
Protection class	I acc. to EN 61800‑5‑1
Touch protection	EN 50274/BGV A3 for the intended purpose
Cooling method	Cooling in compliance with EN 60146: Basic Line Connection Modules, Active Line Connection Modules, Motor Modules: WE - W: Liquid cooling - E: Forced air cooling, drive device outside the equipment Line reactors, motor reactors, dv/dt filters with Voltage Peak Limiter: AN - A: Air cooling - N: Natural cooling (convection)
Ambient conditions	Storage ²⁾	Transport ²⁾	Operation
Ambient temperature	-25 ... +55 °C	-25 ... +70 °C from -40 °C for 24 hours	0 ... +45 °C bis +50 °C see derating data
Relative humidity (condensation not permissible)	5 ... 95 % Class 1K4 to IEC 60721‑3‑1	5 ... 95 % at 40 °C Class 2K3 acc. to IEC 60721‑3‑2	5 ... 95 % Class 3K3 acc. to IEC 60721‑3‑3
Environmental class/harmful chemical substances	Class 1C2 acc. to EN 60721‑3‑1	Class 2C2 acc. to EN 60721‑3‑2	Class 3C2 acc. to EN 60721‑3‑3
Organic/biological influences	Class 1B1 acc. to EN 60721‑3‑1	Class 2B1 acc. to EN 60721‑3‑2	Class 3B1 acc. to EN 60721‑3‑3
Degree of pollution	2 acc. to EN 61800‑5‑1
Installation altitude	≤ 2000 m above sea level without derating; > 2000 m see derating data
Mechanical stability	Storage ²⁾	Transport ²⁾	Operation
Vibration load	Class 1M2 acc. to EN 60721‑3‑1	Class 2M2 acc. to EN 60721‑3‑2	–
Deflection	1.5 mm at 5 ... 9 Hz	3.1 mm at 5 ... 9 Hz	0.075 mm at 10 ... 58 Hz
Acceleration	5 m/s² at >9 ... 200 Hz	10 m/s² at >9 ... 200 Hz	9.8 m/s² at >58 ... 200 Hz
Shock load	Class 1M2 acc. to EN 60721‑3‑1	Class 2M2 acc. to EN 60721‑3‑2	Class 3M4 acc. to EN 60721‑3‑3
Acceleration	40 m/s² at 22 ms	100 m/s² at 11 ms	100 m/s² at 11 ms
Compliance with standards
Conformances/approvals, according to	CE (EMC Directive No. 2004/108/EC and Low Voltage Directive No. 2006/95/EC and Machinery Directive 2006/42/EC for functional safety)
Radio interference suppression	SINAMICS drive converter systems are not designed for connection to the public grid (first environment). Radio interference suppression is compliant with the EMC product standard for variable-speed drives EN 61800‑3, "Second environment" (industrial networks). EMC disturbances can occur when connected to the public power networks.

¹⁾ Higher output frequencies available on request.

²⁾ In transport packaging.

Deviations from the specified class are underlined.

Cooling circuit and coolant quality

The following tables and sections describe the coolant quality requirements for the raw water circuit on the plant side and the deionized water circuit of the liquid-cooled SINAMICS S120 Cabinet Modules on the converter side.

Plant-side raw water circuit (based on VDI 3803)
System pressure with reference to atmospheric pressure, max.	600 kPa
Inlet temperature of liquid coolant	Anti-freeze essential for temperature range between 0 °C and 5 °C
Degree of protection <IP55	0 ... 38 °C without derating >38 ... 43 °C, see derating data
Degree of protection IP55	0 ... 33 °C without derating >33 ... 38 °C, see derating data
Coolant quality
Electrical conductivity	< 2200 μS/cm
pH value	7.5 ... 9
Chloride ions	< 180 mg/l
Sulfate ions	<200 mg/l
Orthophosphate	< 50 mg/l
Dissolved iron	< 3 mg/l
Dissolved copper	< 0.2 mg/l
Biological load	< 50 CFU/ml
SiO2 as silicic acid	< 47 mg/l
Aluminum	< 2.65 mg/l
Fluoride	< 4 mg/l
Total hardness	< 20 (< 40 °C) °dH
Size of entrained particles	≤ 0.5 mm
SK 4.3 (upper limit value of polymer phosphates for untreated additional water)	< 10 mmol/l
Permissible limit values for suspended particles in the coolant	No deposits of solid particles at ≥ 0.5 m/s

Converter-side deionized water circuit
System pressure with reference to atmospheric pressure, max.	600 kPa
Pressure drop at rated volumetric flow	70 kPa
Recommended pressure range	80 ... 200 kPa
Inlet temperature of liquid coolant	Dependent on ambient temperature, no condensation permitted Anti-freeze essential for temperature range between 0 °C and 5 °C
Degree of protection <IP55	0 ... 45 °C without derating >45 ... 50 °C, see derating data
Degree of protection IP55	0 ... 40 °C without derating >40 ... 45 °C, see derating data
Coolant quality
Coolant basis	Deionized water with reduced electrical conductivity according to ISO 3696, quality 3 (with IEC 60993)
Electrical conductivity	<5 μS/cm (0.5 mS/m)
pH value	5 ... 7.5
Components that can be oxidized as oxygen content	<0.4 mg/l
Residue after vaporization and drying at 110 °C	<2 mg/kg

The coolant definition specified here should only be considered as recommendation. For units that have been shipped, the information and data provided in the equipment manual supplied should be observed!

Anti-freeze

Anti-freeze	Antifrogen N	Antifrogen L	Varidos FSK
Manufacturer	Clariant	Clariant	Nalco
Chemical base	Monoethylene glycol	Propylene glycol	Monoethylene glycol
Minimum concentration	20 %	25 %	25 %
Anti-freeze agent with minimum concentration	-10 °C	-10 °C	-10 °C
Maximum concentration	45 %	48 %	45 %
Anti-freeze agent with maximum concentration	-30 °C	-30 °C	-30 °C
Inhibitor content	Contains inhibitors with nitrites	Contains inhibitors that are free of nitrates, amines, borates, and phosphate	Contains inhibitors that are free of nitrates, amines, borates, and phosphate
Biocide action with a concentration of	> 20 %	> 30 %	> 30 %

Biocides prevent corrosion that is caused by slime-forming, corrosive or iron-depositing bacteria. These can occur in closed cooling circuits with low water hardness and in open cooling circuits. Biocides must always be selected according to the relevant bacterial risks. Compatibility with inhibitors or anti-freeze used with them must be checked on a case-by-case basis.

Protection against condensation

With liquid-cooled units, warm air can condense on the cold surfaces of heat sinks, pipes and hoses. This condensation depends on the air humidity and the temperature difference between the ambient air and the coolant.

The water which is produced as a result of condensation can cause corrosion as well as electrical damage such as creepage shorts and flashovers. Since SINAMICS units cannot prevent condensation when it is caused by the prevailing climatic conditions, measures must be implemented in the system configuration or in the customer’s installation in order to preclude the risk of condensation. These measures include the following:

a fixed coolant temperature that has been adjusted to the expected air humidity or ambient temperature ensures that critical differences between the coolant and ambient air temperatures do not develop or
temperature regulation of the coolant as a function of the ambient air temperature

The temperature at which water vapor contained in the air condenses into water is known as the dew point. In order to reliably prevent condensation, the coolant temperature must always be higher than the dew point.

The table below specifies the dew point as a function of room temperature T and relative air humidity Φ for an atmospheric pressure of 100 kPa (1 bar). This corresponds to an installation altitude of 0 to approximately 500 m above sea level. Since the dew point drops as the air pressure decreases, the dew point values at higher installation altitudes are lower than the specified table values. It is therefore the safest approach to engineer the coolant temperature according to the table values for an installation altitude of zero.

Room temperature	Relative air humidity Φ
T	20 %	30 %	40 %	50 %	60 %	70 %	80 %	85 %	90 %	95 %	100 %
10 °C	<0 °C	<0 °C	<0 °C	0.2 °C	2.7 °C	4.8 °C	6.7 °C	7.6 °C	8.4 °C	9.2 °C	10 °C
20 °C	<0 °C	2 °C	6 °C	9.3 °C	12 °C	14.3 °C	16.4 °C	17.4 °C	18.3 °C	19.1 °C	20 °C
25 °C	0.6 °C	6.3 °C	10.5 °C	13.8 °C	16.7 °C	19.1 °C	21.2 °C	22.2 °C	23.2 °C	24.1 °C	24.9 °C
30 °C	4.7 °C	10.5 °C	14.9 °C	18.4 °C	21.3 °C	23.8 °C	26.1 °C	27.1 °C	28.1 °C	29 °C	29.9 °C
35 °C	8.7 °C	14.8 °C	19.3 °C	22.9 °C	26 °C	28.6 °C	30.9 °C	32 °C	33 °C	34 °C	34.9 °C
40 °C	12.8 °C	19.1 °C	23.7 °C	27.5 °C	30.6 °C	33.4 °C	35.8 °C	36.9 °C	37.9 °C	38.9 °C	39.9 °C
45 °C	16.8 °C	23.3 °C	28.2 °C	32 °C	35.3 °C	38.1 °C	40.6 °C	41.8 °C	42.9 °C	43.9 °C	44.9 °C
50 °C	20.8 °C	27.5 °C	32.6 °C	36.6 °C	40 °C	42.9 °C	45.5 °C	46.6 °C	47.8 °C	48.9 °C	49.9 °C

A detailed description of the cooling circuits and the recommended coolant is given in the SINAMICS Low Voltage Engineering Manual.

Liquid-cooled units

Информационные материалы

Basic Line Connection Modules

Active Line Connection Modules

Motor Modules

Характеристика

Derating

Overload capability

Технические данные

General technical specifications

Cooling circuit and coolant quality

Anti-freeze

Protection against condensation