AP13: Crane Drive System

Configuration
Siemens
SINAMICS S120 SLM Sizing and Configuration Industry
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 Table of contents

Table of contents
Legal information ..................................................................................................... 2
1 Introduction .................................................................................................... 4
1.1 Overview ........................................................................................... 4
1.2 Requirement to drive system configuration......................................... 4
2 Premature equipment failure due to parasitic effects ................................... 5
3 Use of SLM as a feeding at Crane's applications .......................................... 6
4 SLM behavior during line fluctuations .......................................................... 8
5 SLM supply voltage level ............................................................................... 9
6 SLM Sizing .................................................................................................... 10
6.1 SLM SIZING using standard load calculation ................................... 10
6.2 SLM SIZING using freeload calculation ............................................ 10
7 Available motor voltage ............................................................................... 12
7.1 Motor voltage with pulse edge modulation PEM ............................... 12
7.2 DC Link voltage for SLM .................................................................. 13
7.3 Calculation of the available motor voltage in SLM applications ......... 13
8 Overview SINAMICS S120 configurations with SLM ................................... 14
9 Appendix....................................................................................................... 15
© Siemens AG 2021 All rights reserved

9.1 Service and support ......................................................................... 15

9.2 Industry Mall .................................................................................... 16
9.3 Application support .......................................................................... 16
9.4 Links and literature .......................................................................... 16
9.5 Change documentation .................................................................... 16

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 1 Introduction

1 Introduction
1.1 Overview
In crane drive applications with SINAMICS S120 three different infeeder options
are available:
• Basic Line Module (BLM), single or double quadrant diode or thyristor bridges
• Smart Line Module (SLM), unregulated 4-quadrant IGBT rectifier - regenerative
feed/feedback unit
• Active Line Module (ALM). a self-commutated 4-quadrant rectifier -
regenerative feed/ feedback, actively controlled line converter,
This document formulates requirements to the configuration of SLM drive systems
for crane applications. The configurations presented are typical for ship-to-shore
and rail-mounted gantry container cranes. In principle they also apply to other
crane types such as bridge- or goliath cranes.

1.2 Requirement to drive system configuration

Drive systems with SLM infeeders need to be configured as follows:
1. Allowed drive system supply voltages 380-480 VAC. Until further notice the
use of 500-690V SINAMICS S120 drive systems is not permitted.
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2. Insulated earth (IT supply):

– removal connection bracket for interference-suppression capacitor from the
line’s phase conductors to ground,
– insulation resistance monitoring is needed to comply with IEC60204-32.
3. Re-inforced winding insulation is necessary for motors with a rated winding
voltage equal to or higher than 500V.
4. Minimal capacitance of the transformer secondary winding to ground
Note: I DT MC CR can provide a detailed requirement specification for the
supply transformer.
5. Minimal earth capacitance in cable connections between inverter and motor:
– use cables with minimum capacitance between phase and earth, e.g.
Prysmian’s PROTOFLEX EMV-FC 2YSLCY-J screened 3x70+3x10 with
290nF/m,
– installation method ‘C’ or ‘E’ as per IEC60204-32, annex B.1.2.

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 2 Premature equipment failure due to parasitic effects

2 Premature equipment failure due to

parasitic effects
Depending on the crane’s mechanical structure and the properties of the electrical
cables used, the cable between the inverter and the motor may have relevant
capacitances (phase-to-earth). In this case the switching of the line-side and motor-
side converters may excite a resonance circuit formed by the inductances and the
cable capacitance (see principle circuit below).

Figure 2-1 Principle circuit common mode oscillation

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If the system components are not compatible, the peak voltage stress on motors
and cables or the peak current stress in IGBT converters and transformers might
lead to premature equipment failure.
Cable installation requirements and length limitations as per “Cabling and Wiring
Guidelines for Cranes”, Rev. 1.1, dated 23. March 2007 are to be observed.
Deviation from the above requirements might be required for certain cranes types,
e.g.
• Ladle cranes fed from distribution busbars
• STS cranes with trolley or hoist motors on the trolley (SPT and MOT design)
For such cases a detailed assessment of the drive system configuration is to be
performed and approval by DI MC GMC CR is required.

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 3 Use of SLM as a feeding at Crane's applications

3 Use of SLM as a feeding at Crane's

applications
Due to the operating principle of the 6-pulse three-phase bridge circuit, the Smart
Infeed causes relatively high harmonic effects on the supply system. The line
current contains a high harmonic content with harmonic numbers h = n * 6 ± 1, with
n = 1, 2, 3, etc. The harmonic currents produced in rectifier operation (motor
operation) are identical as those of the Basic Infeed and have the same spectral
distribution. The Total Harmonic Distortion factor of the current THD(I) is typically in
the range from about 30 % to 45 %.
In regenerative operation, the 5th harmonic decreases significantly but all the
others increase slightly so that the Total Harmonic Distortion factor THD(I) only
decreases by a few percent. The use of Line Harmonics Filters for the reduction of
harmonic effects is not permissible with Smart Infeeds due to the different
spectrums of the current harmonics in rectifier operation (motor operation) and in
regenerative operation.
A reduction of the Total Harmonic Distortion factor (THD)(I) to a value of approx.
10% can only be achieved with 12-pulse circuits, i.e. by supplying two Smart Line
Modules from a three-winding transformer with a 30° phase displacement between
its secondary voltages.
Due to these facts the 12-pulse rectifier circuit is preferred at use of SLM’s into
crane applications.
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A 12-pulse rectifier circuit is created when two identical 6-pulse rectifiers (SLM’s)
are supplied from two different supply systems, whose voltages are out of phase by
30°. This is achieved with the use of a three-winding transformer, whose one low-
voltage winding is star-connected and the other delta-connected.
The harmonic effects can be significantly reduced with 12-pulse circuits as
compared to 6-pulse circuits. Due to the phase shifting of 30° between the two
secondary voltages, the harmonic currents with harmonic numbers h = 5, 7, 17, 19,
29, 31, 41, 43, ... , which are still present in the input currents of the 6-pulse
rectifiers, compensate one another so that theoretically only odd harmonic currents
and voltages that cannot be divided by 3 with the following numbers h occur at the
PCC on the primary side of the three-winding transformer: h = n * 12 ± 1 where n =
1, 2, 3, ... also i.e. h = 11, 13, 23, 25, 35, 37, 47, 49, ...
However, as in practice there is never a perfectly symmetrical load distribution
between the two rectifiers, it must be assumed that harmonic currents with
harmonic numbers h = 5, 7, 17, 19, 29, 31, 41, 43, … are also present with 12-
pulse circuits, but with amplitudes that are maximum 10 % of the corresponding
values of 6-pulse circuits.

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 3 Use of SLM as a feeding at Crane's applications

Figure 3-1 Parallel 12-pulse SLM infeeder concept

As Smart Line Modules have no electronic current sharing control, three-winding

transformer, power cabling and line reactors must meet the following requirements
in order to provide a balanced current:
• Three-winding transformer must be symmetrical, recommended vector groups
Dy5d0 or Dy11d0.
• Relative short-circuit voltage of three-winding transformer uk ≥ 4 %.
• Difference between relative short-circuit voltages of secondary windings Δuk ≤
© Siemens AG 2021 All rights reserved

5 %.
• Difference between no-load voltages of secondary windings ΔV ≤ 0.5 %.
• Use of symmetrical power cabling between the transformer and the Smart Line
Modules (cables of identical type with the same cross-section and length)
• Use of line reactors with a relative short-circuit voltage of uk = 4 %.
A double-tier transformer is generally the only means of meeting the requirements
of a three-winding transformer for this application. Alternative solutions for
obtaining a phase displacement of 30 °, such as two separate transformers with
different vector groups, cannot be used due to the inadmissibly high tolerances
involved.
Due to the phase displacement of 30º between both secondary winding systems
and the control of both systems by separate Control Units, it is generally not
possible to ensure, that both systems contribute equally to the pre-charging of the
connected DC link. In order to prevent the overloading of individual systems during
pre-charging, the 12-pulse parallel connection of Smart Line Modules must be
dimensioned in such a way that each system is individually able to pre-charge the
DC link.
The current reduction from the rated value for individual Smart Line Modules in a
parallel connection is 7,5 %.

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 4 SLM behavior during line fluctuations

4 SLM behavior during line fluctuations

For line supply under-voltages the SLM behaves as outlined in the catalog PM21.
“rated voltage”. The product catalog defines the minimum SLM input voltage levels
for the “400V” voltage range as 3AC380V-10% with a lowest permissible voltage of
3AC380V-15% for less than one (1) minute. The maximum possible rated power is
reduced to 90% of the rated values.
For under-voltages down to 85% of the rated voltage all auxiliary systems work
sufficiently. If the voltage dips are expected to exceed 85 % for both main
contactors and circuit breakers a UPS has to be added for buffering the control
voltage supply to the main switching elements of the SLM. If the undervoltage
occurs longer than 1 min also the fans have to be connected to a UPS. Up to 1
minute the reduction of the cooling (fan speed) is acceptable.
© Siemens AG 2021 All rights reserved

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 5 SLM supply voltage level

5 SLM supply voltage level

As described in product catalog, the maximum SLM input voltage levels for the
“400V” voltage range as 3AC480V+10%.
Based on aspects as outlined in section 3, SLM crane drive systems should to
further notice be engineered using “400V” series inverters (type number 6SL3330-
7TExx-xxxx). In this case motors with a rated winding voltage up to 3AC500V may
be used. Re-inforced winding insulation is necessary for motors equal to or higher
than 500V. The use of 500-690V SINAMICS S120 drive systems is not permitted.
SINAMICS S120 has limitations to the maximum DC-link voltage level as a result of
the sensitivity of the electrolytic capacitors in the converter’s DC-link towards
excessive voltage and the resulting decrease in the life expectancy of voltage-
source frequency converters.
© Siemens AG 2021 All rights reserved

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 6 SLM Sizing

6 SLM Sizing
The power demand of the motor of each motion is calculated from the motor torque
as follows:
1 2
Pmot = 2  n[ ]  Tmot[ Nm] = n[rpm]  T [ Nm]
s 60

6.1 SLM SIZING using standard load calculation

The DC Link voltage must be UDC= 1.5 x ULine

WARNING

The SLM is sized based on the following consideration:

N Pmot _ i  f overload
P =
H _ DC i =1  mot _ i  inv  1,5
where Pmot_i is the mechanical power drawn from the individual motors
running simultaneously in steady state
foverload is the overload factor for motions with coinciding acceleration
mot_i is the efficiency of the individual motor
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inv is the efficiency of the individual inverter (assume 0.985)

PH_DC is the DC Link power using the standard high load duty cycle.
Herewith the DC link current IH_DC can be calculated by the following formula:
P
I H _ DC =
H _ DC

U DC
where PH_DC is the DC Link power using the standard high load duty cycle.
UDC is the DC Link voltage.
The SLM can be chosen according its IH_DC current from the catalog.

6.2 SLM SIZING using freeload calculation

Using the freeload calculation the SLM is sized based on the two following
considerations:
• The average power in the power unit must be calculated for the duration of the
load duty cycle,
• The magnitude of the short-time power must be checked.
The average power of the active line module can be calculated using:
N Pmot _ i
P =
average i =1  mot _ i  inv
where Pmot_i is the mechanical power drawn from the individual motors
running simultaneously in steady state
mot_i is the efficiency of the individual motor
inv is the efficiency of the individual inverter (assume 0.985)

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 6 SLM Sizing

The maximum power can be calculated using the formula:

N Pmot _ i  f overload
P =
max i =1  mot _ i  inv
where Pmot_i is the mechanical power drawn from the individual motors
running simultaneously in steady state
foverload is the overload factor for motions with coinciding acceleration
mot_i is the efficiency of the individual motor
inv is the efficiency of the individual inverter (assume 0.985)
With Paverage and Pmax the SLM can be selected via the required rated SLM input
current:
Paverage Pmax
I Line _ average = and I IN _ max =
3 VLine SLM 3 VLine  SLM
where VLine is the line voltage
SLM is the efficiency of the SLM inverter (assume 0.98)
The SLM can be chosen according its ILine_average and ILine_max current from the
catalog.
© Siemens AG 2021 All rights reserved

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 7 Available motor voltage

7 Available motor voltage

The motor voltage in applications with SLM depends on the line voltage and the
modulation mode of the Motor Modules.

7.1 Motor voltage with pulse edge modulation PEM

At low output frequencies and low depth of modulation, i.e. at low output voltage,
the SINAMICS S120 utilize the space vector modulation SVM option and switch
automatically over to pulse-edge modulation PEM if the depth of modulation
required at higher output frequencies is so high that it can no longer be provided by
space vector modulation (output voltage > 92 % of input voltage).
For PEM the fundamental frequency RMS value of the output voltage can then be
calculated as:

6
VPEM _ max_ theo =  VDCLink = 0,78  VDCLink

where VPem_max_theo is the theoretical maximum possible output voltage
VDCLink is the DC Link voltage
However, the motor voltage then has an unsuitable harmonic spectrum which
causes major stray losses in the motor and utilizes the motor inefficiently. It is for
this reason that pure square-wave modulation is not utilized on SINAMICS
converters. The pulse-edge modulation method used on SINAMICS converters
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permits a maximum output voltage which is only slightly lower than the line voltage,
even when allowance is made for voltage drops in the converter:
VPEM max = 0,745  VDCLink
where VPem_max_theo is the theoretical maximum possible output voltage
VDCLink is the DC Link voltage

NOTE Pulse-edge modulation PEM is only available in vector control mode.

NOTE With the introduction of Firmware version V2.3 and the simultaneous changing of
the hardware, pulse-edge modulation is available as standard for Motor Modules
/ chassis format and Motor Modules /Cabinet Modules format since autumn
2005.

With the introduction of Firmware version V2.5 SP1 and the simultaneous
NOTE
changing of the hardware, pulse-edge modulation is available as standard also
for Booksize units since autumn 2007.

Exceptions:
• Parallel converters on which two or more power units operating in parallel are
supplying one motor with a common winding system. Under these conditions
pulse-edge modulation cannot be selected.
• Converters with output-side sine-wave filter. Pulse-edge modulation cannot be
selected under these conditions.

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 7 Available motor voltage

7.2 DC Link voltage for SLM

The SLM is a line-commutated rectifier / regenerative unit and produces an
unregulated, load-dependent DC link voltage VDCLink from the three-phase line
voltage VLine. Under no-load conditions, the DC link is charged to the peak line
voltage value, i.e. VDCLink = 1.41 • VLine.
When the DC link is loaded, its voltage drops in case of the voltage drop at the 4 %
reactor. At partial-load the DC link voltage will be VDCLink ≈ 1.32 • VLine and at full
load,
V DCLink  1,30  VLine
As the DC link voltage is unregulated, line voltage fluctuations cause the DC link
voltage to fluctuate correspondingly.

7.3 Calculation of the available motor voltage in SLM

applications
With the facts from 8.1and 8.2 the available motor voltage under full load in SLM
application is:
VMotor  0,745  1,30  VVLine  0,97  VLine
where VMotor is the output voltage of the Motor Modules
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The following table shows the calculation of typical line voltage values.

Table 7-1 calculation of typical line voltages

VLine [V] VMotor [V]
3 AC 528 (480+10%) 512
3 AC 516 500
3 AC 480 466
3 AC 400 388
3 AC 380 369
3 AC 342 (380-10%) 332

As the DC link voltage is unregulated, line voltage fluctuations cause the DC link
voltage to fluctuate correspondingly

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 8 Overview SINAMICS S120 configurations with SLM

8 Overview SINAMICS S120 configurations

with SLM
Figure 8-1 Single 12 pulse configuration Smart Line Module (SLM) feeding common DC-
bus.

3AC 380-480 V ±10%

IT-Network

Uk = 4% Uk = 4%

SLM SLM
CU_

CU_

MoMo MoMo MoMo

© Siemens AG 2021 All rights reserved

Figure 8-2 Double 12 pulse configuration Smart Line Module (SLM) feeding common DC-
bus. Typical solution for drive systems where the power rating of one single
12 pulse configuration SLM is sufficient.

3AC 380-480 V ±10%

IT-Network

Uk = 4% Uk = 4% Uk = 4% Uk = 4%

SLM SLM SLM SLM

CU_

CU_

MoMo MoMo MoMo

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 9 Appendix

9 Appendix
9.1 Service and support
Industry Online Support
Do you have any questions or need assistance?
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service and support know-how and portfolio.
The Industry Online Support is the central address for information about our
products, solutions and services.
Product information, manuals, downloads, FAQs, application examples and videos
– all information is accessible with just a few mouse clicks:
support.industry.siemens.com

Technical Support
The Technical Support of Siemens Industry provides you fast and competent
support regarding all technical queries with numerous tailor-made offers
– ranging from basic support to individual support contracts.
Please send queries to Technical Support via Web form:
support.industry.siemens.com/cs/my/src
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SITRAIN – Digital Industry Academy

We support you with our globally available training courses for industry with
practical experience, innovative learning methods and a concept that’s tailored to
the customer’s specific needs.
For more information on our offered trainings and courses, as well as their
locations and dates, refer to our web page:
siemens.com/sitrain

Service offer
Our range of services includes the following:
• Plant data services
• Spare parts services
• Repair services
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• Retrofitting and modernization services
• Service programs and contracts
You can find detailed information on our range of services in the service catalog
web page:
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Industry Online Support app

You will receive optimum support wherever you are with the "Siemens Industry
Online Support" app. The app is available for iOS and Android:
support.industry.siemens.com/cs/ww/en/sc/2067

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 9 Appendix

9.2 Industry Mall

The Siemens Industry Mall is the platform on which the entire siemens Industry
product portfolio is accessible. From the selection of products to the order and the
delivery tracking, the Industry Mall enables the complete purchasing processing –
directly and independently of time and location:
mall.industry.siemens.com

9.3 Application support

Siemens AG
Digital Industries
Motion Control
Cranes
DI MC GMC CR
© Siemens AG 2021 All rights reserved

Frauenauracher Str. 80
91056 Erlangen, Germany
mailto: [email protected]

9.4 Links and literature

Table 9-1
No. Topic
\1\ Siemens Industry Online Support
https://support.industry.siemens.com
\2\ Link to this entry page of this application example
https://support.industry.siemens.com/cs/ww/en/view/48293880
\3\

9.5 Change documentation

Table 9-2
Version Date Modifications
V1.0 03/2009 First version
V1.1 05/2020 Review
V1.2 01/2021 Review

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