Overview

The SINAMICS G120 frequency inverter is designed to provide precise and cost-effective speed/torque control of three-phase 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.

Example: SINAMICS G120, frame sizes FSA, FSB and FSC; each with Power Module, CU240E‑2 F Control Unit and Basic Operator Panel BOP-2

Example: SINAMICS G120, frame sizes FSD, FSE and FSF; each with Power Module, CU240E‑2 F Control Unit and Intelligent Operator Panel IOP

Example: SINAMICS G120, frame size FSGX; with Power Module, CU240E‑2 F Control Unit and Basic Operator Panel BOP-2

Operator-friendly design

SINAMICS G120 is a modular inverter system that essentially comprises two function units:

• Control Unit (CU)
• Power Module (PM)

The Control Unit controls and monitors the Power Module and the connected motor using several different closed-loop control types that can be selected. It supports communication with a local or central controller and monitoring devices.

The Power Module supplies the motor in the power range 0.37 kW to 250 kW (0.5 hp to 400 hp). It features state-of-the-art IGBT technology with pulse-width-modulated motor voltage and selectable pulse frequency. Comprehensive protection functions provide a high degree of protection for the Power Module and the motor.

The Control Units can be combined with the following Power Modules:

Control Units	Power Modules degree of protection IP20
	PM240‑2	PM240	PM250
CU230P‑2	✓	✓	✓
CU240E‑2	✓	✓	✓
CU250S‑2	✓	✓	✓

Safety Integrated

SINAMICS G120 standard inverters are available in different versions for safety-related applications. The PM240‑2 and PM250 Power Modules are already designed for Safety Integrated. PM240 Power Modules, frame size FSGX (i.e. 160 kW/250 hp and higher) are approved only for the Basic Safety functions (STO, SS1, and SBC). A drive can be combined with a Control Unit with safety functions (see overview) in order to create a Safety Integrated drive. The availability of Safety Integrated functions depends on the type of Control Unit.

Control Unit	Basic Safety functions			Extended Safety functions
	STO	SS1	SBC 1)	SLS	SDI	SSM
CU230P‑2	–	–	–	–	–	–
CU240E‑2	✓	–	–	–	–	–
CU240E‑2 F	✓	✓	–	✓	✓	✓ 2)
CU250S‑2	✓	✓	✓	✓ 3)	✓ 3)	✓ 3)

1) The SBC function can be utilized only if a Safe Brake Relay is installed.

2) SSM possible only for CU240E‑2 DP‑F / CU240E‑2 PN‑F Control Units with PROFIsafe.

3) With license for Extended Safety functions.

Basic Safety functions (certified according to IEC 61508 SIL 2, and EN ISO 13849‑1 PL d and Category 3)

• Safe Torque Off (STO)
  to protect against active movement of the drive
• The PM240‑2 Power Modules, frame sizes FSD to FSF additionally offer STO acc. to IEC 61508 SIL 3 and EN ISO 13489‑1 PL e and Category 3.
• Safe Stop 1 (SS1)
  for continuous monitoring of a safe braking ramp
• Safe Brake Control (SBC) is used to safely control a holding
  brake. When enabled, SBC is always activated at the same time as STO. The Safe Brake Relay is used for SBC.

Extended Safety functions (certified according to IEC 61508 SIL 2 and EN ISO 13849‑1 PL d and Category 3)

• Safely Limited Speed (SLS)
  for protection against dangerous movements on exceeding a speed limit
• Safe Direction (SDI)
  This function ensures that the drive can only rotate in the selected direction.
• Safe Speed Monitoring (SSM)
  This function signals if a drive operates below a specific speed/feed velocity.

Basic Safety and Extended Safety functions can be activated via PROFIsafe or by means of the safety inputs.

None of the safety functions require a motor encoder and they are thus cheaper and easier to implement. Existing systems in particular can be simply updated with safety technology without the need to change the motor or mechanical system.

The Safe Torque Off (STO) function can be used without restriction for all applications. The SS1, SLS, SSM and SDI functions are only permissible for applications where the load can never accelerate when the inverter is switched off. They are therefore not permitted for applications involving pull-through loads such as hoisting gear and unwinders.

Additional information is provided in chapter Highlights, section Safety Integrated.

Efficient Infeed Technology

The innovative Efficient Infeed Technology is employed in PM250 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. For control cabinets, an additional temperature rise can be avoided and the amount of space required can be reduced due to the fact that components such as braking resistors, braking choppers and line reactors can be eliminated. Further, wiring and engineering costs are significantly reduced. At the same time, energy consumption can be reduced and ongoing operating costs noticeably reduced.

Additional information is provided in chapter Highlights, section Efficient Infeed Technology.

Innovative cooling concept and varnishing of electronic modules

The new cooling system and varnishing of the electronic modules significantly increases the service life or useful life of the device.

• Disposal of all heat losses via an external heat sink
• Consequential convection cooling of the Control Unit, electronic modules are not located in the air duct
• All cooling air from the fan is directed through the heat sink

Energy efficiency

Integrated technologies help when optimizing the energy usage of the plant or system referred to the particular application:

• Energy-efficient vector control with or without sensors
• Automatic flux reduction with U/f ECO mode
• Integrated energy saving computer

Additional information is provided in chapter Highlights, section Energy efficiency.

Benefits

• Modularity ensures flexibility for a drive concept that is fit for the future
  • Control Unit can be hot-swapped
  • Pluggable terminals
  • The modules can be easily replaced, which makes the system extremely service friendly
• The integrated safety functions significantly reduce the costs when integrating drives into safety-oriented machines or systems
• Communications-capable via PROFINET or PROFIBUS with PROFIdrive Profile 4.0
  • Plant-wide engineering
  • Easy to handle
• The innovative circuit design (bidirectional input rectifier with "pared-down" DC link) allows the kinetic energy of a load to be fed back into the supply system when PM250 Power Modules 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
• Integrated USB interface for simplified, local commissioning and diagnostics
• Application-specific functions for pumps, fans and compressors
  Integrated are, e.g.:
  • 4 freely-programmable PID controllers
  • Application-specific wizards
  • Pt1000/LG-Ni1000 temperature sensor interface
  • 230 V AC relay
  • 3 freely-programmable digital time switches
• With CU250S‑2 Control Units: Integrated positioning functionality (basic positioner EPos) supports process-related implementation of positioning tasks with a high dynamic response. Positioning can be implemented with an incremental and/or absolute encoder (SSI)
• With CU250S‑2 Control Units: Encoder interfaces DRIVE‑CLiQ, HTL/TTL/SSI (SUB‑D) and resolver/HTL (terminal)
• With CU250S‑2 Control Units: Vector control with or without sensors
• Integrated control functionality by using BICO technology
• An innovative cooling concept and coated electronic modules increase robustness and service life
  • External heat sink
  • Electronic components are not located in air duct
  • Control Unit that is completely cooled by convection
  • Additional coating of the most important components
• Simple unit replacement and quick copying of parameters using an optional Operator Panel or an optional 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 for static/pulsed signals for universal control via digital inputs
• Fast engineering and commissioning by using standard engineering tools such as SIZER for Siemens Drives, STARTER, SINAMICS Startdrive, and Drive ES – STARTER is integrated into STEP 7 using Drive ES Basic, with all of the benefits of central data management and totally integrated communication
• Certified worldwide for compliance with CE, UL, cUL, C-Tick (RCM) and Safety Integrated according to IEC 61508 SIL 2 and EN ISO 13849‑1 PL d and Category 3
• The PM240‑2 Power Modules, frame sizes FSD to FSF additionally offer STO acc. to IEC 61508 SIL 3 and EN ISO 13489‑1 PL e and Category 3.

G120 Model