The SINAMICS G120 frequency inverter is designed to provide precise and cost-effective speed/torque control of AC motors.
With different device versions (frame sizes FSA to FSGX) in a power range from 0.37 kW to 250 kW (0.5 hp to 400 hp), it is suitable for a wide variety of drive solutions. Examples of SINAMICS G120, frame sizes FSA, FSB and FSC; each with Power Module, Control Unit and Basic Operator Panel Examples of SINAMICS G120, frame sizes FSD, FSE and FSF; each with Power Module, Control Unit and Basic Operator Panel Examples of SINAMICS G120, frame size FSGX; with Power Module
SINAMICS G120 is a modular inverter system comprising a variety of functional units. The main units are
• the Control Unit (CU)
• the Power Module (PM)
The Control Unit controls and monitors the Power Module and the connected motor using several different control types that can be selected. It supports communication with a local or central
control and monitoring devices.
The Power Module supplies the motor in a power range 0.37 kW to 250 kW (0.5 hp to 400 hp). The Power Module is controlled by a microprocessor in the Control Unit. State-of-the-art IGBT
technology with pulse-width modulation is used to achieve the highest degree of reliability and flexible motor operation. Comprehensive protection functions provide a high degree of protection for
the Power Module and the motor.
Furthermore, a large number of additional components is available, such as:
• Intelligent Operator Panel (IOP) for parameterizing, diagnosing, controlling and copying drive parameters
• Basic Operator Panel (BOP) for parameterizing, diagnosing,
• controlling and copying drive parameters
• Line filters, Classes A and B
• Line reactors
• Braking resistors
• Sine-wave filters
• Output reactors
The SINAMICS G120 standard inverters are available in a number of different versions for safety-related applications. All Power Modules are already designed for Safety Integrated. A Safety
Integrated Drive can be created by combining a Power Module with the appropriate Fail-safe Control Unit.
The SINAMICS G120 fail-safe frequency inverter provides four safety functions, certified in accordance with EN 954-1, Category 3 and IEC 61508 SIL 2:
• Safe Torque Off (STO) to protect against active movement of the drive
• Safe Stop 1 (SS1) for continuous monitoring of a safe braking ramp
• Safely Limited Speed (SLS) for protection against dangerous movements when a speed limit is exceeded
• Safe Brake Control (SBC) for driving motor brakes which are active in the de-energized state, e.g. motor holding brakes
The functions “Safe Stop 1” and “Safely Limited Speed” can both be implemented without having to use a motor sensor or encoder; the implementation cost is minimal. Existing systems in particular
can be updated with safety technology without the need to change the motor or mechanical system.
The safety functions “Safely Limited Speed” and “Safe Stop 1”are not certified for pull-through loads as in the case of lifting gear and winders.
Additional information is provided in the part Highlights, section Safety Integrated.
Efficient Infeed Technology
PM260 Power Modules. This technology allows the energy produced by motors operating in generator mode connected to standard inverters to be fed back into the supply system. Additional
cooling and additional space requirement in the control cabinet can be avoided as components such as braking resistors, brake choppers and line reactors are not required. Further, wiring and
engineering costs are significantly reduced. At the same time, considerable savings can be achieved in terms of energy consumption and operating costs.
Additional information is included in the part Highlights, section Efficient Infeed Technology.
Innovative cooling concept and paint finish of electronic modules
The innovative cooling concept and coated electronic modules significantly increase the service life and usage time of the device. These features are based on the following principles:
• The power loss is exclusively dissipated using an external heat sink
• Electronic modules not located in air duct
• Standardized convection cooling of Control Unit
• All cooling air from the fan is directed through the heat sink
STARTER commissioning tool
The STARTER commissioning tool simplifies the commissioningand maintenance of SINAMICS G120 inverters. The operator guidance combined with comprehensive, user-friendly functions for the
relevant drive solution allow you to commission the device quickly and easily.
• Modularity ensures flexibility for a drive concept that is fit-forthe-future
o Modules can be replaced under voltage (hot swapping)
o Pluggable terminals
o The modules can be easily replaced, which makes the system extremely service friendly.
o The safety functions make it easier to integrate drives into safety-oriented machines or plants
• Communications-capable via PROFINET or PROFIBUS with PROFIdrive Profile 4.0
o Reduced number of interfaces
o Plantwide engineering
o Easy to handle
• The innovative circuit design (bidirectional input rectifier with “pared-down” DC link) allows the kinetic energy of a load to befed back into the supply system when Power Modules PM250and
PM260 are used. This feedback capability provides enormous potential for savings because generated energy no longer has to be converted into heat in a braking resistor
• Innovative SiC semiconductor technology ensures that when a PM260 Power Module is used, the inverter is more compact than a comparable standard converter with an optional sinewave filter
for the same power rating An innovative cooling concept and coated electronic modules increase robustness and service life
o External heatsink
o Electronic components are not located in air duct
o Control Unit that is completely cooled by convection
o Additional coating of the most important components
• Simple unit replacement and quick copying of parameter using the optional Basic Operator Panel or the optional MMC memory card
• Quiet motor operation as a result of the high pulse frequency
• Compact, space-saving design Software parameters for simple adaptation to 50 Hz or 60 Hz motors (IEC or NEMA motors)
• 2-/3-wire control (static/pulsed signals) for universal control via digital inputs (only CU240 Control Units)
• Engineering and commissioning with uniform engineering tools such as SIZER, STARTER, and Drive ES: ensure fast engineering and easy commissioning – STARTER is integrated in STEP with
Drive ES Basic with all the advantages of central data storage and totally integrated communication
• Certified worldwide for compliance with CE, UL, cUL, c-tick and Safety Integrated according to IEC 61508 SIL 2
SINAMICS G120 is ideally suited
• as a universal drive in all industrial and commercial applications
• e.g. in the automotive, textiles, printing, and chemical industries
• for higher-level applications, e.g. in conveyor systems
SINAMICS G120 standard inverters are modular frequency inverters for standard drives. Each SINAMICS G120 comprises two operative units – the Power Module and Control Unit. Each Control Unit
can be combined with each Power Module.
Guidelines for module selection
Select a suitable Control Unit (depending on the required communication,hardware and software version and safety functionality)
Select a suitable Power Module (depending on the power and technology required)
Select the optional and additional components. There are a large number of components for expanding the system (e.g. line-side power components, DC link components, load-side power components, and supplementary system components). However, it should be noted that not all of the components are required for all of the Power Modules (example: Braking resistors are not required for the PM250 and PM260 Power Modules!). The precise data is provided in the technical specifications tables of the particular components.
The Control Unit performs closed-loop control functions for the inverter. In addition to the closed-loop control, it has additional functions that can be adapted to the particular application through
Two series of Control Units are available for SINAMICS G120 corresponding to their software packages (CU230 and CU240). Each Control Unit comprises a defined I/O quantity structure, a special
fieldbus interface and possible additional safety functions. The following Control Units and accessories are available for standard SINAMICS G120 inverters:
CU230 Control Units
The CU230P-2 Control Units have been specifically designed for pump, fan and compressor applications. The following three versions are available:
• CU230P-2 HVAC
• CU230P-2 DP
• CU230P-2 CAN
CU240 Control Units
Several Control Units are available in different versions:
• CU240S DP
• CU240S DP-F
• CU240S PN
• CU240S PN-F
MMC memory card (not available for Control Unit CU240E)
The parameter settings for an inverter can be stored on the MMC memory card. When the plant is serviced, it is immediately ready for use again after, for example, replacement of the frequency
inverter and transfer of the memory card data. The associated slot is located on top of the Control Unit.
The following Power Modules are available for the SINAMICS G120 standard inverters:
PM240 Power Modules
PM240 Power Modules (0.37 kW to 250 kW / 0.5 hp to 400 hp) feature an integrated brake chopper (for frame size FSGX external) and are designed for drives without energy recovery capability.
Generator energy produced during braking is converted to heat via externally connected braking resistors.
PM250 Power Modules
PM250 Power Modules (7.5 kW to 90 kW / 10 hp to 125 hp) have an innovative circuit design which allows line-commutated energy recovery back into the line supply. This innovative circuit permits
generator energy to be fed back into the supply system and therefore saves energy.
PM260 Power Modules
PM260 Power Modules (11 kW to 55 kW / 15 hp to 75 hp) also have an innovative circuit design which allows line-commutated energy recovery back into the line supply. This innovative circuit
permits generator energy to be fed back into the supply system and therefore saves energy. The PM260 Power Modules also have an integrated sine-wave filter that limits the rate of rise of voltage
and the capacitive charging/discharging currents usually associated with inverter operation.
Line-side power components
The following line-side power components are available for SINAMICS G120 standard inverters:
With one of the additional line filters, the Power Module reaches a higher radio interference class.
Line reactors (for PM240 Power Modules only)
A line reactor reduces the system perturbations caused by harmonics. This particulary applies in the case of weak line supplies (line suply short-circuit power uK > 1 %).
Recommended line components
This is a recommendation for additional line-side components, such as fuses and circuit-breakers (line-side components must be dimensioned in accordance with IEC standards). Additional information
about the listed fuses and circuit breakers can be found in Catalogs LV 1 and LV 1 T.
DC link components
The following DC link components are available for the SINAMICS G120 standard inverters:
Braking Modules (only for PM240 Power Modules, frame size FSGX)
A Braking Module and the matching external braking resistor are required to bring drives with a PM240 Power Module, frame size FSGX to a controlled standstill in the event of a power failure (e.g.
emergency retraction or EMERGENCY STOP Category 1) or limit the DC link voltage during a short period of generator operation. The Braking Module includes the power electronics and the
associated control circuit.
Braking resistors (for PM240 Power Modules only)
Excess energy in the DC link is dissipated in the braking resistor. The braking resistors are designed for use with PM240 Power Modules. They are equipped with an integrated brake chopper
(electronic switch). There is an optional plug-in Braking Module for frame size FSGX.
Load-side power components
The following load-side power components are available for the SINAMICS G120 standard inverters. This means that during operation with output reactors or sine-wave filters, longer, shielded motor
cables are possible and the motor service life can be extended:
Output reactors (for PM240 and PM250 Power Modules only)
Output reactors reduce the voltage stress on the motor windings. At the same time, the capacitive charging/discharging currents, which place an additional load on the power unit when long
motor cables are used, are reduced.
Sine-wave filter (not for PM260 Power Modules)
The sine-wave filter limits the rate of rise of voltage and the capacitive charging/discharging currents that usually occur with inverter operation. An output reactor is not required.