Siemens Answers with SINAMICS DCP - Innovative DC-DC Converters for Industrial and Smart Grid Applications

SINAMICS DCP News

SINAMICS DCP takes Silver

120 kW SINAMICS DCP has won the Silver Award in the Energy Management Category in Plant Engineering Magazine’s 2016 Product of the Year competition.


SINAMICS DCP Power Converter

The new generation of bidirectional DC-DC converters - SINAMICS DCP - combines Siemens’ extensive knowledge of DC technology with the advantages of the SINAMICS drives family, including well-proven tools and components from SINAMICS DCM drives.

SINAMICS DCP, a scalable DC-DC Power Converter suited for both industrial and smart grid applications, is a combined buck / boost converter in one device.

Overlapping voltage ranges at the input and output are possible by means of 4Q operation. This means that the DC output voltage can be lower or higher than the DC input voltage and for variable voltage levels, current can flow in both directions making SINAMICS DCP the ideal solution for charging and discharging batteries and supercapacitors..

Thanks to its high switching frequency, SINAMICS DCP is very compact and lightweight.

Flexible Integration and a Wide Range of Combination Options

The high efficiency of SINAMICS DCP maximizes the overall energy fed into the public grid, island grid, microgrid or the internal power system of a factory when it is used to interconnect DC energy sources (e.g. photovoltaics, fuel cells) and energy storage systems (e.g. rechargeable batteries, SuperCaps) to the common DC bus of a grid converter/infeed inverter such as a SINAMICS S120 Active Line Module.

A PROFIBUS communication interface is included as standard. The interfaces of the Advanced CUD can be supplemented using additional modules - such as the optional CBE20 for PROFINET or EtherNet/IP™.

The BOP20 basic operator panel is available for simple commissioning and local operator control.

STARTER software is used for the parameter assignment and diagnostics.


Characteristics

  • SINAMICS DCP controls the electrical power flow between two Direct Current systems

  • SINAMICS DCP can be operated  with current control or voltage control

  • SINAMICS DCP’s main application is to control the electrical power flow between two DC systems, e.g. between a common DC bus and a stationary battery
    – from the common DC bus (DCP input, terminals P1 and N1) to a battery (DCP output, terminals P2 and N2) – this is called motoring operation and means positive current
    – from the battery (DCP output, terminals P2 and N2) back to the common DC bus (DCP input, terminals P1 and N1) – this is called generating operation and means negative current

  • Bidirectional power flow is possible

  • The voltages of both DC systems may have any values between 0 and +800V

  • The voltages in the two DC circuits are independent of one another

  • The electrical power flow, controlled by a signed (+ or -) current setpoint specification, is possible regardless of the voltages in the two DC circuits (in the nominal range)

  • The current setpoint and control signals can be specified via fieldbus (PROFIBUS – standard; PROFINET or EtherNet/IP – optional via CBE20 Communication Board) or hardwired signals


Features & Benefits

Feature

Benefit

Combined Buck/Boost Converter in One Device

Optimized adaption to energy storage systems and the common DC bus of an infeed inverter or grid converter

Bidirectional

Energy flow in both directions, charge and discharge a battery or supercapacitor with one device

High Efficiency - Up to 98.6%

Maximum  energy harvest

Wide Voltage Range

Along with bidirectional power flow capability and high efficiency, SINAMICS DCP provides an optimal interconnection of energy storage systems (rechargeable batteries, SuperCaps) to the common DC bus of a grid converter, such as an Active Line Module

Different infeed sources (solar, fuel cells, wind, etc.) can be connected to the common DC bus of an Active Line Module, via SINAMICS DCPs and Motor Modules, and realize a multi generator system

Scalable Power from 30 to 480 kW

High currents by connecting up to 4 devices in parallel at the input and / or output

High Switching Frequency

Low current ripple and high voltage quality

Compact and lightweight design, control unit and reactors are built-in

High Flexibility with 4Q Operation

A 4Q converter can be applied as a boost or as a buck converter where the DC output voltage can be lower or higher than the DC input voltage, e.g. charging and discharging a battery

Allows overlapping voltage ranges at the input and output

High Maximum Voltage
1,000 VDC (Imax = 5 A for 30 sec, every 5 min.
(only 30 kW DCP)

To connect PV arrays under no-load conditions

Functionality can be Expanded Using Additional SINAMICS Components, e.g., SINAMICS S120 Active Line Module

Different infeed sources (solar, wind, etc.) can be connected together to realize a multi generator system

Integrated Systems from One Source

Well-known and easy operating philosophy from the SINAMICS AC and DC drives family


Software Functions

  • Voltage Control (even in parallel operation)
    Constant voltage based on a setpoint, can be used as an adjustable voltage source

  • Extended Voltage range:  0 V – 800 V DC
    Voltage as low as 0 V to charge SuperCaps

  • Parametrizable battery charging characteristic
    Optimum adaptation to various types of battery chemistries and their varying charging requirements

  • Voltage regulation on DC bus
    Highest process reliability by maintaining and controlling the DC bus voltage

  • Automatic DC bus buffering
    Fast supply of the DC bus from a battery, in case of line supply failure to an infeed unit (SINAMICS S120 ALM), to maintain uninterrupted operation of a motor connected to a frequency converter (SINAMICS S120 Motor Module)

  • Variable pulse frequency
    To reduce switching losses, optimize efficiency and control current ripple

  • Temperature controlled fans (only available for 120 kW DCP)
    To optimize efficiency in partial –load range and reduce noise

  • Three selectable Overload profiles
    Power peaks can be briefly provided, peak shaving applications can be realized
    - Increased current, 0 - 20%, (available for 30 kW DCP and 120 kW DCP)
    - Low overload (only available for 120 kW DCP)
    - High overload (only available for 120 kW DCP)

  • Parametrizable overload reaction based on heat sink temperature
    Derating of switching frequency, derating of current or switch-off

  • EtherNet/IP industrial communication interface
    To integrate into other automation networks

  • Local adjustment of voltage and current actual values via control unit
    The voltage and current values that the DCP displays can be adjusted so that they correspond to externally measured values

  • Input of an external temperature sensor via control unit
    Three different temperature sensors possible

  • Integrated Maximum Power Point (MPP) Tracker
    To maximize the power yield of Photovoltaic arrays

  • PV array flying restart
    The no-load voltage of a PV array can be drawn into the continuous running duty range of SINAMICS DCP


Technical Information

30 kW DCP

120 kW DCP

Voltage Range

0 - 800 VDC

Max. Voltage Range

1,000 VDC (Imax = 5 A for 30 sec, every 5 min)

920 VDC (with derating)

Power

30 kW @ Imax = 50 A,
Vin = Vout = 600 V DC

120 kW @ Imax = 200 A,
Vin = Vout = 600 V DC

Current Ripple

3%

Scalability

4x parallel, Input and / or Output

External Supply Voltage

24 V DC, I = 5 A

24 V DC, I = 20 A

Max. Efficiency

> 98%

Temperature Range

32 – 104°F (0 - 40°C)
Up to 131°F (55°C) with derating

Installation Altitude

Up to 6,500 ft. (2,000 m) without derating
Up to 16,400 ft. (5,000 m) with current / voltage derating

Communication

PROFIBUS, PROFINET, EtherNet/IP, DRIVE CLiQ with OALINK connection to CU320-2

Closed-Loop Control

Current, voltage and power

Control Module

Own Control Unit

Electrical Isolation

No

Protection Degree

IP20

IP00

Weight

84 lbs. (38 kg)

260 lbs. (118 kg)

Dimensions ( H x W x D)

23.6 x 6.1 x 21.5 in (600 x 155 x 545 mm)

35.4 x 8.1 x 19.7 in (900 x 205 x 500 mm)

Certifications / Approvals

CE, cURus, EAC, RCM

Standards

IEC 62109-1

IEC 61800-5-1

IEC 61800-3

UL 508C

UL 61800-5-1

CSA C22.2 No. 274

Need more Technical?


Overlapping Voltage Ranges at the Input and Output are Possible by Means of 4Q Operation

The main application of SINAMICS DCP is to control the electrical power flow between two DC systems:

  • From a DC bus (input side 1, terminals P1 & N1) to a stationary battery (output side 2, terminals P2 & N2).
    This is called motoring operation and means positive current

  • From a battery (output side 2, terminals P2 & N2) back to the DC bus (input side 1, terminals P1 & N1).
    This is called generating operation and means negative current

The power flow in both directions (from the DC bus to the battery and from the battery to the DC bus) is called bidirectional.

The voltages in the two DC circuits are independent of one another.

The electrical power flow, controlled by a signed (+ or -) current or power setpoint specification, is possible regardless of the voltages in the two DC circuits (in the nominal range).

Definition of a 4-Quadrant Converter

A 4Q converter can be applied as a boost or buck converter

The DC output voltage can be lower or higher than the DC input voltage, i.e. charge and discharge a battery

P1, N1 (DC Bus – Input) and P2, N2 (Battery – Output) refer to the input and output terminals of the converter

Input Voltage
Terminals P1, N1

Output Voltage
Terminals P2, N2

Voltage Flow

Battery

Q1

Higher

Lower

Input >> Output

Charging

Q2

Higher

Lower

Output >> Input

Discharging

Q3

Lower

Higher

Output >> Input

Discharging

Q4

Lower

Higher

Input >> Output

Charging


Typical Applications

Industrial Energy Efficiency

  • Alternative to Braking Choppers, e.g. crane & hoist applications
    When a load is lowered, excess energy can be temporarily stored in rechargeable batteries or SuperCaps. As a consequence, this stored energy can then be used for the next hoisting operation instead of being simply wasted using a braking resistor. As a consequence, for electric crane applications, a significant amount of energy can be saved; and for diesel-powered crane systems, a smaller diesel generator can be used

  • Coupling DC Buses at Different Voltage Levels
    DC buses at different voltage levels can be intelligently coupled. As a consequence, only one infeed point (grid converter such as an Active Line Module) is required

  • Battery Test Stands
    Using the bidirectional DC-DC converter, battery test stands can be implemented to test the performance of batteries / rechargeable batteries

  • Mining Conveyor Belts
    SINAMICS DCP is especially interesting for conveyor belts in the mining sector, as connected energy storage devices (Batteries, SuperCaps) can be used to store energy when braking, which can later be utilized to cover load peaks. This means that smaller diesel generators can be used and operated at their optimum operating point, with the corresponding reduction in costs and fuel consumption


Battery Storage Solutions / Energy Management

  • BESS (Battery Energy Storage Systems)
    To implement stationary battery energy storage systems by connecting battery modules to the DC-DC converter. The energy is then fed into the grid or standalone supply via a common DC bus and a grid converter

  • Wind and Photovoltaic
    To buffer excess energy from wind turbines and PV systems - the excess energy is temporarily stored in batteries. 
      - SINAMICS DCP is also suitable for exciting synchronous generators from a DC bus

  • Electric Vehicle Infrastructure - electric cars, buses, trains, boats, etc.
    for charging and discharging batteries in a stationary infrastructure


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