Power section components testing and replacement

Power section components / Component replacement / Test box
Training objectives:
You are informed about
• the constructional design of power section
components of SINAMICS-cabinet-units
• Constructional design and wiring of the
power block
You are familiar with the particularities of the

replacement of the main components
You can test the functions of the power block

with the test box
SITRAIN Training for

SINAMICS Date:
File:
06/03/2007
ABU DHABI: Page 14 - 1 Automation and Drives
Siemens AG 2007. All rights reserved.
Power section components / component replacement / test box

Content Page
Principle of operation / S150............................................................................................................ 4
Pulse width modulation..................................................................................................................... 5
Principle of operation of an inverter.................................................................................................. 6
Space vector modulation.................................................................................................................. 7
Trace-samples of the inverter output voltage.................................................................................... 8
Active Line Module: rectifying and voltage step up mode.................................................................. 9
Active Line Module: regenerating operation...................................................................................... 10
Rectifying and regenerating operation / Reactive power compensation............................................. 11
”Elimination“ of voltage harmonics by Clean Power Filter................................................................. 12
”Elimination“ of voltage harmonics by Clean Power Filter................................................................. 13
Forming of DC-link capacitors.......................................................................................................... 14
Design of a power block................................................................................................................... 15
Combining power modules to create different frame sizes................................................................ 16
Power modules as part of power units.............................................................................................. 17
Power block for ALM (AC DC), MM (DC AC)................................................................................ 18
Electronic sub assembly................................................................................................................... 19
Replacement of spare parts.............................................................................................................. 20
continued on page 3

SINAMICS Date:
File:
06/03/2007
Power section components / component replacement / test box
Content Page
Verifying the de-energized condition................................................................................................. 21
Frame size F, G, H and J................................................................................................................ 22
Fan / Installation and voltage supply................................................................................................. 23
Installation of the Control Interface Board (CIB) / i.e. G150............................................................... 24
Installation of the power block / i.e. G150.......................................................................................... 25
Power block support for safe replacement of the power block........................................................... 26
Shipping device for the power block................................................................................................. 27
Test box and power block................................................................................................................. 28
Circuit diagram................................................................................................................................. 29
Auxiliary supply 24VDC ................................................................................................................... 30
1. Testing the rectifier function......................................................................................................... 31
2. Testing the inverter function......................................................................................................... 32
3. Testing the current transformers................................................................................................... 33
Test of the semiconductors............................................................................................................... 34
Inverter test by applying ohmic load ................................................................................................. 35
Rectifier and inverter analysis by current measurement.................................................................... 36

SINAMICS Date:
File:
06/03/2007
Principle of operation / S150
U, f = constant U, f = variable
U Udc U
AC - DC DC - AC
i.e. 3AC, 400V, 50 Hz controlled to setpoint voltage
Pre-charging Rectifier DC-link Inverter
U1 U2
V1 V2
W1 W2
Line Motor
DC-link

SINAMICS Date:
File:
06/03/2007
Pulse width modulation
2 kHz --> 500 µs
Pulse width modulation / Active Line Module Pulse width modulation / Motor Module
Framesize Switching frequency Switching frequency Current contr.

Active Line Module Motor Module sample time
s
losse
F, G (400V) 4.0 kHz 2.0 kHz (.... 8.0 kHz) 250 μs hing
Switc form ance
F, G (690V) 4.0 kHz 1.25 kHz (.... 5.0 kHz) 400 μs
am ic per
Dyn
H, J (400V) 2.0 / 4.0 kHz 1.25 kHz (.... 5.0 kHz) 400 μs
1,25 pulse frequency (kHz) 8
Booksize 8.0 kHz 2.5 / 4.0 kHz (.... 16 kHz) 400 / 250 μs

SINAMICS Date:
File:
06/03/2007
Principle of operation of an inverter

U.L1L2 + U.ZK
switching state
1 2 3 4 5 6 1
1 2 3
L1 - U.ZK
DC-link L2
L3
U.L2L3 + U.ZK
motor
switching state
4 5 6
1 2 3 4 5 6 1
- U.ZK
switching transistor nr. potential condition on resulting

state (X = closed) motor terminals voltage pointer
1 2 3 4 5 6
- L1
Z1
1 X X X
Z1
Z2
L2 + + L3
- Z6
2 X X X
Z2
- +
Z3
+
Z5
3 X X X Z3
- + Z4
X X X
+ -
special
state Z0
X X X
+ + - -

SINAMICS Date:
File:
06/03/2007
Space vector modulation
u(t)
Z1 Z1
Z2 Z6 Z2
Z3 Z5
Z4
t.P t.P t.P

Z1 Z1 Z1
t t t
Z2 Z2 Z2
t t t
resulting pointer position : 45 degrees resulting pointer position: 30 degrees resulting pointer position : 15 degrees
resulting voltage : i.e. 40% resulting voltage : i.e. 50% resulting voltage : i.e. 60%

SINAMICS Date:
File:
06/03/2007
Trace-samples of the inverter output voltage
0.5 ms 0.5 ms 0.5 ms 0.5 ms 0.5 ms 0.5 ms 0.5 ms 0.5 ms 0.5 ms 0.5 ms 0.5 ms
0.5 ms 0.5 ms 0.5 ms 0.5 ms

SINAMICS Date:
File:
06/03/2007
Active Line Module: rectifying and voltage step up mode S150
VDC=1,5 Vn Simplified principle of operation:
1. Two line phases are short circuited.

VU-V
2. The short circuit current is limited by the
step up reactors.
3. At the same time the magnetic field of the
reactor acts as energy buffer.
4. The short circuit current is interrupted.

5. The large current gradient results in a high
Vind= di/dt self induction voltage on the reactor.
VU-V 6. The self induction voltage is added to the
currently valid line voltage. The resulting
voltage exceeds the DC-link voltage.
7. Current flows to the DC-link.
8. After 250 μs the discussed cycle restarts
(for a pulse frequency of 4 kHz).
In rectifying operation the Active Line Module operates basically like the Motor Module in
regenerative operation. The line supply takes the position of the motor.
In rectifying operation current flow through the free wheeling diodes dominates.

SINAMICS Date:
File:
06/03/2007
Active Line Module: regenerating operation S150
VDC=1,5 Vn
Simplified principle of operation:
VU-V
1. At any moment the DC-link voltage is higher
than the line voltage.
2. By switching on two transistors the positive
and negative DC-link bus bar are connected
to a matching line phase.
3. Energy is fed back to the line.
4. To control regeneration one transistor is

switched off.
5. The step up reactor maintains the current
flow through a matched free wheeling diode.
6. After 250 μs the discussed cycle restarts
(for a pulse frequency of 4 kHz).
In regenerating operation the Active Line Module operates basically like the Motor Module in
motor operation.
In regenerating operation current flow through the transistors dominates.

SINAMICS Date:
File:
06/03/2007
Rectifying and regenerating operation / Reactive power compensation
i.line u.line
Z i.line u.ALM u.line
u.ALM
u.line u.ALM u.line
u.ALM
Z i.line u.line
u.ALM u.line
u.ALM
u.line
i.reactive = +20% (inductive reactive load)
u.ALM
i.reactive ϕ ind.
u.line i.line
i.line
i.active
ϕ ind.
i.apparent i.reactive = 20% u.line

(of i.ALM.rated) i.line u.line
i.line
i.active = function (load)

ϕ ind.

SINAMICS Date:
File:
06/03/2007
”Elimination“ of voltage harmonics by Clean Power Filter
Clean Power Filter

SINAMICS Date:
File:
06/03/2007
”Elimination“ of voltage harmonics by Clean Power Filter
New Clean Power Filter
Considerably more compact design

The filter is designed for the drive not to exceed the tolerance-limits up to
the 50th harmonic and in the low-frequency range of 2...9 kHz in rated
operation. On the line connection point the values of disturbance voltage
read a maximum of 1%.
0,12%
Clean Power Technology
0,08%
0,04%
0,00%
5, 7 11, 13 17, 19 23, 25

SINAMICS Date:
File:
06/03/2007
Forming of DC-link capacitors
Frame sizes C to F
voltage ON ON ON
%
storage time less than 1 year no measure required

storage time 1 to 2 years energize the DC-link for one hour
prior to switching on the inverter
storage time 2 to 3 years form up the DC-link capacitors
according to the characteristic
storage time more than 3 years form up the DC-link capacitors
according to the characteristic
time t [h]

SINAMICS Date:
File:
06/03/2007
Design of a power block G150 / G130
Pre-charging
• B6-diode-precharging
• thyristor firing pulses
• basic interferance
RECT + 1 INV
RECT + 3 INV
suppression
2 INV
Rectifier
• B6-thyristor-bridge,
fully controlled
size F, G size H
DC-link
• capacitors
• braking chopper
RECT
INV
INV
INV
Inverter
• IGBT+ FW-diodes
• IGD: controls IGBTs
• heat sink
• balancing size J
• current transformers
High efficiency IGBTs / DC-link bus bar with low inductance / very compact design

SINAMICS Date:
File:
06/03/2007
Combining power modules to create different frame sizes

frame sizes of power modules
components of
power modules
F G H J
nic
c tro le
ele odu
m
k
loc
rb
we te
po pla
ort
pp
su
fan

SINAMICS Date:
File:
06/03/2007
Power modules as part of power units
components of
power modules
- 1 power block 4 power blocks

nic power
ctro le
ele odu FS: F module FS: J
m
k 110KW 560KW/480V
loc 800kW/690V
e rb e
po
w lat
rt p
pp
o The power section (Power Unit) of SINAMICS G150/G130 is an AC-AC
su
fan unit called Power Module (PM). Its design is basically identical to the power
modules of SINAMICS S150 (G150/G130 with thyristor rectifier, however).

SINAMICS Date:
File:
06/03/2007
Power block for ALM (ACÆDC), MM (DCÆAC) S150
Features: IGD-board,
¾ state of art IGBT technology IGBT
¾ DC-link bus bar with low inductance current transformer
¾ very compact in design
heat sink
¾ thermal model for high reliability
Rectifier / Inverter:
¾IGBT+ FW-diodes
nt
¾IGD: controls IGBTs

Fro
¾heat sink
¾current transformers
DC-link:
DC-link
¾capacitors
bus bars
¾braking chopper (option)
capacitor battery
Power block serves as:
¾ Active Line Module (ALM) as AC/DC-power-block
¾ Motor Module (MM) as DC/AC-power-block
Both power blocks are identical in hardware; they differ in:
¾ MLFB, terminal assignments and data of the power-block.
The required difference in functionality is provided by software.

SINAMICS Date:
File:
06/03/2007
Electronic sub assembly
Fib
re-o
ptic
3a Power-
2 supply
3
3b
3 DRIVE-CLiQ Base plate

sockets
1
3 Communication Interface board CIB

3a Adaptation Interface board AIBO (shunts, limit value monitoring)
3b Power Stack Adapter PSA (generation of the inverter pulse pattern)
Extended functionality of the CIB-FW starting with V2.3 and CIB-MLFB ...-3 (starting with HW-version M):
edge triggered modulation / safe stop / parallel operation of power sections up to 4xLM and 4xMM per CU320

SINAMICS Date:
File:
06/03/2007
Replacement of spare parts
Adapted to the converter-cabinet as ordered an

individual spare parts list is generated for the
customer.
Spare parts of SINAMICS G150/S150 basic unit

(respectively of MM4 PX) are:
Power Blocks
Electronic module with CU320
Fan, fan transformer and terminal strip X9
Further spare parts of SINAMICS-cabinets are:

Terminal Module TM31
Operator Panel AOP30
Power supply 24V SITOP
Mechanical and electrical components
depending on selected options
Fan replacement: after max. 35 000 operating hours at

40 °C ambient temperature.
Collected dust has to be removed every year.

SINAMICS Date:
File:
06/03/2007
Verifying the de-energized condition
Measuring points up to 690 VAC Measuring points

fan supply motor connection
example frame size G frame size F
Measuring points up to 1200 VDC

DC-link voltage
example frame size F

SINAMICS Date:
File:
06/03/2007
Frame size F, G, H and J
1 DC-link 4 Control Unit 7 Sensor Module 10 PE-bus bar

2 DC-coupling 5 Unit fan 8 Motor connection 11 EMC-screen-
3 Motor Module 6 Terminal strip 9 Auxiliary voltage bus bar

SINAMICS Date:
File:
06/03/2007
Fan / Installation and voltage supply
The fan is supplied with

voltage via contactor;
control is provided via
module CIB.
After taking out two screws and

after removing the single phase
supply the fan slides out
towards the front.

SINAMICS Date:
File:
06/03/2007
Installation of the Control Interface Board (CIB) / i.e. G150
PSB
Module CIB is a spare part as

such. The parameterization of
After removal of the CU320 and after 1 support of CU the power stack data via BIN-
sliding out the power supply board 2 optical and signal cables files may only be done in
(PSB) towards the front module CIB 3 DRIVE-CLiQ cables factory and in authorized
can be removed from the PSB. 4 mounting screws PSB service centers.

SINAMICS Date:
File:
06/03/2007
Installation of the power block / i.e. G150
1 line-, motor connection

2 DC-link connection
3 upper mounting screws
4 lower mounting screws
5 support PSB / 5 plug
6 plugs for optical cables
7 plug of thermistor
8 fan mounting screws

SINAMICS Date:
File:
06/03/2007
Power block support for safe replacement of the power block
1 Mounting screws
2 Hight adjustment
B
Watch out for horizontal (A) respectively
vertical (B) position; make sure the
vertical supports cannot slip; carefully
tighten the screw handles!
(weight of power blocks up to 100 kg)

SINAMICS Date:
File:
06/03/2007
Shipping device for the power block
1 4
1.
1. Remove
Remove the the power
power block
block
following the guideline
following the guideline
2.
2. Pull
Pull itit out
out onto
onto the
the power
power
block support
block support
3.
3. Put
Put thethe power
power block
block onon
5 the ground (2 persons!)
the ground (2 persons!)
4.
4. Mount
Mount the the bottom
bottom ofof the
the
2 shipping
shipping device
device onon the
the
side
side of of the
the power
power block
block
5.
5. Tilt
Tilt the
the assembly
assembly to to the
the
side
side
6.
6. Put
Put thethe ESD
ESD cover
cover in
in
place
place and and close
close the
the cover
cover

SINAMICS Date:
File:
06/03/2007
Test box and power block

SINAMICS Date:
File:
06/03/2007
Circuit diagram
Basic
Basic Line
Line Module
Module
Motor
Motor Module
Module
nicht bei BLM S120 Cabinet
(Pre-charging),
(Pre-charging), thyristor
thyristor
drive
drive board
board TDB,
TDB, thyristors
thyristors
Inverter:
Inverter: Current
Current
Testbox 6AG 1064 – 1AA04 – 0AA0 Cables 6AG 1065 – 1AA04 – 0AA0 IGD,
IGD, IGBT,
IGBT, UCE
UCE transformers
transformers

SINAMICS Date:
File:
06/03/2007
Auxiliary supply 24VDC
-A24 TDB
-X244: 1.. 6
+24V
-A20 -X204: 1.. 6

-A29 IGD
AIBO -X291: 1.. 2
-X208: 1.. 15
+24V
+24V
-G27 -X278: 1 .. 15 -X271: 2 .. 1
-X9: 2 1 PSB
+24V
SITOP
-X9: 1 2
24V, 3A

SINAMICS Date:
File:
06/03/2007
1. Testing the rectifier function
X244
TDB
L1,
L1, L2,
L2, ...
...
L+
L+,
L+, L+,
L+, ...
... RVL
L1
L2
L3
RVL
L-
pre-charging operation rectifier

rectifier (diodes) (thyristors) with TDB
24VDC

SINAMICS Date:
File:
06/03/2007
2. Testing the inverter function
T1 T2 T3
L+
US
T1 UCE
T2
T3
IGD
X291 LS
U1
L+ 1 L-
L+
T1 IGBTs and control

T1 // T2
T2 /T3
/T3 U2
1
L-
L-
U3
24VD 1
C
press the key
EXECUTE for a
maximum of 2
seconds only!

SINAMICS Date:
File:
06/03/2007
3. Testing the current transformers
X23
CT
T1 T2 T3
L+ T1
T2
T3
M
IGD
X291 CT
U1
1 L-
L+
L+
U2
1
L-
L-
U3
24VDC 1
press the key
EXECUTE for a
maximum of 2
seconds only!

SINAMICS Date:
File:
06/03/2007
Test of the semiconductors

This
This test
test identifies
identifies the
the function
function of
of the
the
2999 DC +
rectifier- and of the free-wheeling-
rectifier- and of the free-wheeling-
diodes;
diodes; itit reveals
reveals short-circuited
short-circuited
IGBTs.
IGBTs.
In
In the
the rectifier
rectifier of
of units
units of
of larger
larger
L1 U
L2
power
power ratings
ratings shorted
shorted thyristors
thyristors
V
are
are
L3 indicated by R = “0 Ohm“,
indicated by R = “0 Ohm“, W shorted
shorted
diodes
diodes by by RR == “R.pre-charge“.
“R.pre-charge“.
DC -
2999
DC +
L1 U
L2 V
L3 W
DC -

SINAMICS Date:
File:
06/03/2007
Inverter test by applying ohmic load
L1
L2
L3
U In
In V/Hz-operation
V/Hz-operation thethe output
output current
current is
is
limited
limited to
to aa maximum
maximum but
but not
not
monitored
monitored any any other
other way.
way.
Consequently
Consequently an an inverter
inverter can
can bebe
operated
operated without
without load
load respectively
respectively atat
very
very low
low load
load which
which allows
allows aa functional
functional
f test
test of
of the
the inverter.
inverter.

SINAMICS Date:
File:
06/03/2007
Rectifier and inverter analysis by current measurement
At
At low
low load
load the
the current
current peaks
peaks of
of the
the line
line
current are unsymmetrical.
current are unsymmetrical.
The
The measurement,
measurement, however,
however, shows
shows thatthat all
all
diodes
diodes become
become conductive.
conductive.
High
High frequency
frequency noise
noise andand ripple
ripple superposed
superposed
on
on the
the sinusoidal
sinusoidal output
output current
current are
are
consequences
consequences of of the
the pulse
pulse width
width modulated
modulated
output
output voltage.
voltage.
The
The output
output current
current has has toto be
be fairly
fairly
symmetrical
symmetrical for
for all
all three
three phases;
phases;
pre-condition:
pre-condition: ii >> 0.1
0.1 i.rated.
i.rated.
Missing
Missing half
half cycles
cycles indicate
indicate aa faulty
faulty inverter.
inverter.
A
A missing
missing output
output phase
phase oror aa phase
phase current
current
considerably
considerably smaller
smaller than
than the
the others
others indicates
indicates
unsymmetrical
unsymmetrical load
load or
or aa faulty
faulty inverter
inverter

SINAMICS Date:
File:
06/03/2007

Power section components testing and replacement

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Power section components testing and replacement

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Power section components / Component replacement / Test box

You are familiar with the particularities of the

You can test the functions of the power block

SITRAIN Training for

Power section components / component replacement / test box

SITRAIN Training for

SITRAIN Training for

Principle of operation / S150

i.e. 3AC, 400V, 50 Hz controlled to setpoint voltage

Pre-charging Rectifier DC-link Inverter

SITRAIN Training for

2 kHz --> 500 µs

Framesize Switching frequency Switching frequency Current contr.

SITRAIN Training for

Principle of operation of an inverter

switching transistor nr. potential condition on resulting

SITRAIN Training for

t.P t.P t.P

SITRAIN Training for

Trace-samples of the inverter output voltage

0.5 ms 0.5 ms 0.5 ms 0.5 ms

SITRAIN Training for

VDC=1,5 Vn Simplified principle of operation:

1. Two line phases are short circuited.

4. The short circuit current is interrupted.

SITRAIN Training for

Active Line Module: regenerating operation S150

4. To control regeneration one transistor is

SITRAIN Training for

i.apparent i.reactive = 20% u.line

i.active = function (load)

SITRAIN Training for

”Elimination“ of voltage harmonics by Clean Power Filter

Clean Power Filter

SITRAIN Training for

New Clean Power Filter

 Considerably more compact design

SITRAIN Training for

Forming of DC-link capacitors

storage time less than 1 year no measure required

SITRAIN Training for

SITRAIN Training for

Combining power modules to create different frame sizes

SITRAIN Training for

- 1 power block 4 power blocks

SITRAIN Training for

Power block for ALM (ACÆDC), MM (DCÆAC) S150

¾IGD: controls IGBTs

SITRAIN Training for

3 DRIVE-CLiQ Base plate

3 Communication Interface board CIB

SITRAIN Training for

Replacement of spare parts

Adapted to the converter-cabinet as ordered an

Spare parts of SINAMICS G150/S150 basic unit

Further spare parts of SINAMICS-cabinets are:

Fan replacement: after max. 35 000 operating hours at

SITRAIN Training for

Measuring points up to 690 VAC Measuring points

Measuring points up to 1200 VDC

SITRAIN Training for

Frame size F, G, H and J

Considerably more compact design