Siemens Answers with Products and Solutions for General Motion Control Applications

With a clear focus on the needs of customers, Siemens approach to every application of Motion Control - no matter how general or specific - combines innovation and automation to create best-in-class products and optimal solutions for any machine. Machine builders, system integrators, and end users can leverage Siemens’ broad motion control portfolio as well as a global network, which that includes technical support services, application support services, capable distributors, solution partners, and more.

Why Choose Siemens?

Cost Savings in Configuration, Commissioning, Control and Diagnostics 
Through Totally Integrated Automation

Highly Scalable, Flexible Solutions
With SIMATIC, SIMOTION and SINAMICS that reduce the number of components and complexity of the machine automation systems, and offer greater standardization of parts

Global Footprint
No matter what you import or export, Siemens has the worldwide experience, and that includes local resources in over 190 countries ready with technical resources and spare parts


 

Chill out with Siemens solutions for refrigeration

Refrigeration systems - trends

The growing need for increased efficiency in the use of natural resources as a result of rising energy / water costs and strict environmental regulations, force manufacturers of industrial and commercial refrigeration equipment to continuously look for new solutions. Yet with challenges come opportunities — to design efficient and innovative machines that give your company a competitive edge, while adding value to your equipment and your customers.

System efficiency
Manufacturers are pushed by cost-conscious users and by regulators to improve the energy efficiency of refrigeration systems. The US Department of Energy has set minimum efficiency standards (Energy Policy Act) for certain commercial systems. More policy changes are likely as consumers and governments continue to strive to lower energy costs and reduce the impact of energy use on the environment.

Key Department of Energy legislation affecting the refrigeration industry includes the National Appliance Energy Conservation Act, the National Environmental Policy Act, and the Toxic Substances Act.

Looking to the sun to cool things off?
The commercial refrigeration system market is also witnessing an increasing use of solar-powered systems and this technology is anticipated to play a major role in addressing energy scarcity issues.

Why Siemens?

  • Siemens is at the forefront of addressing these trends in the refrigeration industry, including the rapid adoption of Internet of Things (IoT), compatible commercial refrigeration systems that enhance system output, government initiatives to support the utilization of eco-friendly refrigerants and continued advancements in energy-efficient products

  • Siemens can provide the complete solution for automation and control needs, including software simulation for new designs through its PLM group

  • For decades Siemens has been a global leader in developing integrated energy-efficient products and solutions for refrigeration applications. By purchasing many components from a single source, efficient interoperability is guaranteed and interface problems are minimized. Without system interruptions, seamless remote maintenance is simplified, which plays a significant role in considerably reducing downtimes in the rare event that faults occur


Refrigeration products & applications

Industrial refrigeration systems
Siemens' General Motion Control business has developed innovative products and solutions that can be customized to meet the growing needs of refrigeration systems, including:

Product types

Refrigerant types

Used in...

Cooling towers

Condensers / evaporators

Chillers

Ammonia

CO 2

HFCs / HCFC / HC

Fruits and vegetables processing

Meat, poultry and fish processing

Dairy and ice-cream processing

Beverage refrigeration

Refrigerated warehouses

Chemicals and pharmaceuticals

Refrigerated transportation

Commercial complexes (hospitals, hotels, schools)

Commercial refrigeration systems

Product types

Used in...

Refrigerated transportation systems

Freezers and coolers

Cold storage

Refrigerated display cases

Ice machines

Supermarkets

Convenience stores

Warehouses

Distribution centers

Hospitals

Hotels

Schools


Why VFDs for refrigeration?

Since their inception, refrigeration systems were designed to run under full-load conditions. However, demands are almost always well below full (about 96% of the time), so it is rare that full-motor capacity is required. Traditionally, during average conditions, compressor motors run either constantly at higher speeds than necessary or frequently cycle on and off. This scenario wastes a considerable amount of energy, with added wear on motors, contactors, and other components.

Traditional compressor motor scenario

Compressor when powered by a VFD / motor

All this starting and stopping motors and continually accelerating them to full speed is extremely inefficient compared to a system that uses variable frequency drives (VFD). Drives-based systems use only the energy required, are able to reach peak loads when needed, accelerate smoothly, and maintain temperatures with more stability than traditional systems. They are also quieter.

Variable Refrigerant Flow (VRF) systems

VRF systems are cost-effective HVAC systems that offer benefits like energy-savings, increased comfort, design and installation flexibility, lower maintenance costs and quiet operation. These features have been the main drivers of VRF technology adoption in Asia, Europe and South America for the past several decades.

Because of inverter-driven scroll compressor technology, the inverter compressor varies its motor rotation speed and capacity, reducing the total power consumption (because the system operates only at the levels needed to maintain a constant, comfortable indoor environment).

Example commercial VFR applications

  • Healthcare facilities

  • Education

  • Retail / shopping complexes

  • financial sector and insurance (BFSI)


Quieter operation

Reduced sound levels are requested by users, particularly in commercial installations. Manufacturers minimize sound level by utilizing VFDs on fans and compressors to ramp them up and down smoothly, as well as encapsulating the fans blades without compromising the performance. Sound levels are also greatly reduced because the inverter compressor ramps up and down smoothly. The condenser fan rarely runs at full speed and is designed for quiet performance.

How loud is refrigeration?

20 dB(A)

30 dB(A)

60 dB(A)

70 dB(A)

80 dB(A)

Refrigeration system...

VRF ducted unit

VRF wall-mounted indoor unit

VRF commercial outdoor unit

Residential 3-ton HVAC unit

Air-cooled industrial chiller

As compare to a...

Recording studio

Whisper

conversation

Vacuum cleaner

Garbage disposal


Pump, fan and compressor applications from a single source - the power of integrated systems

Totally Integrated Automation (TIA)

With TIA Siemens is the only manufacturer that offers a seamless and integrated portfolio of products, systems, and solutions that are perfectly coordinated with one another. This means more productive engineering, efficiency, and a higher degree of profitability across all processes (by minimizing complexity and costs over the complete equipment lifecycle).

All of the sub-steps — as well as the information flow across all production levels, from the field level up to the company supervisory level — can be fully integrated. This means more productive engineering, efficiency and a higher degree of profitability across all processes. As a result of this integration and unification, Totally Integrated Automation also plays a
significant role in minimizing costs over the entire lifecycle — and reduces the complexity of industrial plants and systems.

Integrated Drive Systems (IDS)

This consistent approach for the complete drive train is particularly characterized by the concept of threefold integration — horizontal, vertical and comprehensive lifecycle integration for improved reliability, productivity and efficiency.

Siemens Integrated Drive Systems are the only true, one-stop solution for entire drive systems worldwide.

> Learn more at the Siemens Integrated Drives Systems website - usa.siemens.com/ids


Reasons to use Siemens drives for refrigeration

  • SINAMICS variable frequency drives) are equipped with built-in PID control loops to provide exceptional performance of process variables such as temperature, pressure and flow — either as a stand-alone device or networked with other equipment for building automation control systems

  • Savings in operating costs can be achieved by running a system at an optimal efficiency point; reducing energy consumed, water used and wear-and-tear on mechanical components

  • Cooling towers and similar systems operated in noise-sensitive environments also benefit from reduced noise levels due to soft starting and optimum speed operation. Running the fan slower can prevent icing in cold weather. Additionally, if necessary, VFDs can also reverse cooling tower fans and keep the heat in the tower. Brakes, anti-ratcheting devices and time delays can also be eliminated

  • Prevention of icing in cold weather

  • Elimination of brakes, anti-ratcheting devices and time delays

Energy-savings
Hibernation mode and ECO mode functions are available as standard on SINAMICS drives. ECO mode automatically adapts the motor flux to minimize energy consumption during low dynamic load cycles. Hibernation mode only operates the motor when the machine requires it to, minimizing energy consumption while extending the motor / machine lifetime. Siemens can provide competitive selling advantages to OEM equipment by standardizing their system with SINAMICS G120 drives and SIMOTICS VSD4000 synchronous reluctance motors. This package provides the highest drive / motor system efficiency in the industry (IE4 acc. to EN 50598-2), allowing end-users to enjoy significant energy-savings on variable torque applications throughout the equipment’s lifecycle.

Maintenance
By using a memory card to back-up / restore parameter sets, minimum knowledge is required to replace drives. In addition, the modular design of the SINAMICS G120 allows for quick replacement of only the affected component without the need for re-commissioning. Remote monitoring via PLCs provides increased maintenance and uptime.

Integrated Safety
Avoid personnel and equipment accidents when using Siemens best-in-class, integrated safety solutions.

Engineering
No-cost engineering software for the commissioning, troubleshooting and maintenance of SINAMICS drives

Circuit protection
SINAMICS V20 and SINAMICS G120 family are UL/CSA tested for high SCCR ratings and provide equipment protection against short-circuit faults when bundled with UL248 fuses or Siemens manual starter protectors (MSPs) and molded case circuit breakers (MCCBs).

Choosing the right drive

Choices mean flexibility in function and cost

SIMOTICS VSD4000

SINAMICS G120 modular vector drives are the go-to product for both stand-alone and integrated refrigeration equipment — wide power and voltage range, options for different protocols, up to 4 PID controllers, push-through installation and maintenance-friendly.

Siemens can bundle SINAMICS G120 with SIMOTICS VSD4000 synchronous reluctance motors for maximum energy efficiency vs. traditional induction motors when operating at rated load or partial load ranges.

SINAMICS G120C compact vector is the little brother of SINAMICS G120 - where space is tighter and a more economical drive will do.

SINAMICS V20 is an option for stand-alone systems up to 40 HP. The new SINAMICS V20
Smart Access accessory is an exclusive solution where you can use a PC, smartphone, or tabled over Wi-Fi for V20 commissioning, troubleshooting and system diagnostics.

SINAMICS application examples

Siemens has ready-to-run application examples for refrigeration applications, including wiring diagrams and parameter descriptions. Sample configurations for connecting SINAMICS drives with SIMATIC PLCs include hardware, software and wiring examples, installation instructions for the supplied S7 project, drive parameterization and HMI sample projects.

Customer benefits

  • Provides a basis for customer-specific machine configurations

  • Optimal leveraging of TIA advantages

  • Free download via the Siemens Online Support Portal: www.siemens.com/sinamics-applications

SINAMICS application examples for refrigeration

SINAMICS V20

PID control
The SINAMICS V20 drives feature an embedded technology controller. Based upon this controller, temperature, pressure, flow and many other process variables’ actual value can be controlled as the same as the setpoint. This includes recommendations for configuring, parameterizing and optimizing control loops with the PID controller.

SINAMICS G120

Closed-loop controlled cooling tower fans
This application is used to completely set the drive parameters for the “fans to control the cooling circuit” application. It includes a standard connection circuit diagram for the control wiring, a script that can run in the STARTER commissioning software, as well as additional functions, which are used for subsequent parameterization

Pressure-controlled compressor
Fixed speed compressors with a storage tank are being increasingly replaced by compressors with variable speed drives, which are able to control the pressure needed in a narrow frame. Energy-intensive over-compression with fixed speed compressors and storage tank is avoided. In addition, high-starting currents and starting torques with repeated switching on and off are of the past when using variable speed compressor drives.

Pressure-controlled pump
Pressure-controlled pumps are used in piping systems when pressure must be kept constant even when the flow fluctuates. This predominantly involves water supply systems, where the water pressure at the house connection points must be kept constant and where it must be ensured that there is sufficient water in the top floors of high-rise buildings. These so-called pressure boosting stations comprise one or several centrifugal pumps, which using a PID controller control the pressure by changing the speed.

SINAMICS V20

SINAMICS G120
SINAMICS G120C *

Energy savings

ECO mode / flux reduction
reduces motor currents saving energy during low load cycles

Hibernation mode
the drive is automatically switched on and off depending upon the process requirements, thereby extending the wear on your pumps, blowers and motors

Display of the electrical energy saved
in either kWh, CO 2 or currency without the need for power measurement equipment

Cascade
drives are switched on and off in stages depending upon the process requirement

Efficient Infeed Technology
an innovative feature, that also means that compact drives are also capable of energy recovery

Reducing motor speed
can save energy up to 80% at 50% of speed

Easy installation

Several mounting options
wall-mount, push-through, side-by-side

Easy operator control
using built-in BOP (basic operator panel)

Smart Access
wireless commissioning, operation and diagnostics via mobile device or laptop with web server module

Higher power rating
in a smaller space

Easy maintenance
with modular design and flexible control cabinet configurations with push-through versions (applies to SINAMICS G120 only)

Commissioning of standard applications
using application-specific wizards — knowledge about parameters is not necessary

Simple commissioning on-site
using a handheld terminal

Free-of-charge advanced commissioning
using STARTER / SINAMICS Startdrive software

Easy to use

Parameter settings can easily be transferred
from one unit to another

Integrated RS485 communication interface
for USS and MODBUS RTU

Connection and application macros
to simplify I/O configuration

Keep Running Mode
provides higher productivity by automatic adaptation in case of unstable line supplies

Robust
wider voltage range, better cooling design and coated PCB increase robustness of drive in difficult environments, such as ambient temps up to 140º F (60º C)

Compliance with environmental class 3C2
for frames ABC (3C3 with SIPLUS; 3C3 is standard for frames DEF)

Integrated safety with easy setup
(STO2, SS12, SBC2, SLS3, SDI3, SSM3)

Integrated energy recovery
simple setup efficient infeed technology

Positioning capability
(EPOS)

Integral part of Totally Integrated Automation (TIA)
with interfaces for PROFINET and PROFIBUS — coupling to third-party systems via USS / Modbus RTU, BacNet MS / TP and EtherNet/IP TM

* G120, G120C includes all of the benefits of the V20 plus the additional items noted. 2Functions for stopping the drive safely (STO – Safe Torque Off; SS1 – Safe Stop 1; SBC – Safe Brake Control). 3Functions for safely monitoring the motion of a motor (SLS – Safe Limited Speed; SDI – Safe Direction; SSM – Safe Speed Monitor).