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SINAMICS G120

The modular inverter Energy-efficient, safe and rugged

Brochure June 2011

Answers for industry.

SINAMICS Drives

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SINAMICS G1202

SINAMICS G120

The modular, safe and energy-efficient inverter system

Application: Drives in machinery construction

SINAMICS G120 is the universal drive in the complete indus-

trial and trades areas, in vertical markets such as mechanical

engineering, automotive, textile, printing and packaging,

chemical industry as well as in higher-level applications such

as, for example in conveyor technology, in the steel, oil & gas

and offshore sectors as well as renewable energy applications.

It's a perfect fit in central architectures

For standard applications:

The SINAMICS G120 inverter has a modular design and

comprises a Control Unit (CU) and Power Module (PM)

for the power range from 0.37 kW to 250 kW.

The wide range of available components makes it easy foreach user to configure their own, optimum inverter. The rele-

vant modules are simply combined in accordance with the

hardware, communication or safety technology requirements.

The G120 system undergoes continuous further development

to expand it with new components and options:

n Safety Integratedn Energy efficiencyn Harsh environments and endurancen User-friendly from installation to maintenance

SINAMICS G120 belongs to the SINAMICS drive family

for innovative, future-oriented drive solutions

Wide range of power ratings from 0.12 kW to 120 MW

Both in low-voltage as well as medium-voltage versions

Seamless integrated functionality by using common

hardware and software platforms

One standard engineering for all drives

- SIZER for engineering

- STARTER for parameterizing and commissioning

High degree of flexibility and the ability to be combined

SINAMICS offers the optimum drive for every drive application

and all drives can be configured, parameterized, commis-

sioned, and operated in the same standard way.

Highlights

Mechanical system

n Modular designn Innovative cooling concept for a higher degree of

ruggedness

Electronics

n Energy recovery, low harmonics fed back into theline supply, energy-saving, no braking resistor

n Semiconductor temperature monitoringn Safety Integrated (STO, SS1, SLS, SDI, SSM) without

encoder

n Interchangeable MMC memory cardCommunication

n PROFIBUS, PROFINET, PROFIsafe, Modbus RTU,CANopen, USS, BACnet MS/TP

n Integrated in Totally Integrated Automation

Medium voltageLow voltage

SINAMICS G SINAMICS S SINAMICS GM/SM/GL

0.12 1500 kW 0.12 4500 kW 0.8 120 MW

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SINAMICS G120 3

With Efficient Infeed Technology

Unique feature worldwide in the inverter compact class:

Regenerative feedback in small, light and low-cost devices.

For applications in which a braking resistor is used: e.g. appli-

cations with vertical movements, drives for forklift trucks, pro-

cessing machines with a high moment of inertia, centrifuges,

renewable energies (water power, wind power).

Energy efficiency

Inverters save energy through systematic, application-

specific, closed-loop control of the speed.

Additionally, it is possible to feed back energy in generating

mode under braking conditions.

Moreover, integrated energy-saving functions can reduce

electricity supply costs even further.

V/fEco mode: for reducing the motor currents in the partial

load range; for energy savings of up to 40% Hibernation mode: inverter is switched on and off auto-

matically in accordance with process requirements

DC link topology: reduces the line current through a high

active power component

Moreover, integrated energy-saving functions can reduce

electricity supply costs even further.

V/fEco mode: for reducing the motor currents in the partial

load range; for energy savings of up to 40%

Hibernation mode: inverter is switched on and off auto-

matically in accordance with process requirements DC link topology: reduces the line current through a high

active power component

Safety Integrated

Safety technology is increasingly playing an important role in

drive and automation technology.

In its class, SINAMICS G120 offers integrated safety functions

according to EN 60204 that are unique worldwide.

Safety technology integrated in the standard drives can be

used with low associated costs. In compliance with the stand-

ards with a simultaneous increase in the productivity of the

plant or system and easy to engineer, handle and maintain.

Standard

Technology

Efficient Infeed

Technology

Line reactorandbraking resistor

Configurationoverheadandinstallation costs

Generatedharmonics

Heat generatedwhen braking

Required

Standard

Standard

Yes

Not required

Low

Minimal

No

Power consumptionandpower infeed

Energy efficiency

Standard

Standard

Approx. 22%

less

Good

Safe, electrical

shutdown by means of

Safe Torque Off (STO)

Safe, specific

stopping by means of

Safe Stop 1 (SS1)

Safely Limited Speed

(SLS)

Safe

Direction of Rotation

(SDI)

Safe Speed Monitor

(SSM)

Benefits

n Prevents the drive fromaccidentally starting

(no electrical isolation

between the motor and

inverter)

n Drive is safely brought intoa no-torque condition

n Drive is quickly stoppedand and safely monitored

n Independent and continu-ous monitoring ensures

the shortest possible

response time

n An encoder is not required

n The drive speed is reducedand continuously moni-

tored

n An encoder is not required

n The function ensures thatthe drive can only rotate

in the selected direction.

n The function warns whena drive is working below

a specified speed/

feed rate.

Applications

n Baggage/package convey-ing, delivery, removal

n Motion with low position-ing accuracy andno axis synchronism

n Saws, pay-off stands,grinding machines, cen-

trifuges, hoisting gear,

extruders, high-bayracking units, trolleys, ...

n Presses, punches,conveyor belts, grinding

machines, ...

n Directly working at theplant or system during op-

eration, in the setting-up

mode or when carrying

out maintenance work

n Stacker cranes, presses,pay-off stands...

n Grinding machines,drills, milling machines

Applicationexample

Conveyor belt:

n Possibility of dynamicallychanging the velocity

n The intrinsic weight of thesystem brakes it after a

suitably short time

n Fast restartafter a fault

Saw:

n Safe brakingas quickly as possible

n Increased process speedthrough short waiting

periods

n The safe status message"standstill reached"

is sent to the control

Press:

n Monitoring the speedwhile the operator

is in the hazard area

n Safe setting-up operationwith limited, maximum

speed

Loading gantry:

n A hazard area is madeaccessible to the operator

while the machine is

moving away from the

operator.

Milling tool:

n Unlocking of a protectivecover when a non-critical

speed limit is undershot.

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SINAMICS G1204

SINAMICS G120

Convincing standard advantages of the system

Functions Benefits

Modularity

Freely selectable combination of Power Module (PM) and

Control Unit (CU)

Numerous possible combinations of PM and CU

Simply plug on CU to re-commission

Power range can be easily extended

Only the functions actually required have to be purchased

One system for support when selecting

(SIZER, DT Configurator)

Minimal learning time

Modules can be replaced under voltage (hot swap) Re-commissioning is not necessary, only plug on the CU

PM and CU can be replaced separately Service-friendly, no need for full re-installation

CU variant with integrated safety functionality STO Low-cost standard variant for most common basic functionswithout additional components

Controlled via terminals or PROFIsafe

Power modules with Efficient Infeed Technology

from 0.37 to 95 kW

At low power ratings, the benefits of regenerative feedback

and high dynamics can be used

User-friendly installation and commissioning

Integrated USB port for engineering Intuitive connecting simplifies the engineering

Plug-in IOP (Intelligent Operator Panel),

including door mounting kit

Quick commissioning without expert knowledge

Minimization of maintenance times

Plug-in BOP-2 (Basic Operator Panel) Easy basic commissioning without parameter list

2-line display for clear presentation

Remote maintenance/diagnostics and parameterization Simplified, central commissioning/maintenance

Reduced costs as service personnel assignments are no longer

required

Slot for micro memory card (MMC) Data backup for easy replacement

Communication (PROFIBUS, PROFINET, Modbus RTU, CANopen, USS, BACnet)

Standard network structure

Many nodes and network topologies

Easy to handle

Fewer interfaces

Plant-wide engineering

Advantages of IT technology for production (industry) Software updates

Wireless communication using industrial wireless LAN

Directly integrated into the inverter High performance

Application-specific module for the chemical industry

SiC technology for 690 V High thermal load capacity (small heatsinks)

Increased ruggedness

Compact through an integrated sine-wave fi lter Long unshielded cables permissible

16 kHz pulse frequency Bearings do not have to be insulated

Power unit with regenerative feedback capability

Extremely low bearing currents

All the advantages of regenerative feedback are available

START

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5

Functions Benefits

Application-specific modules for pumps, fans, compressors

Application-specific wizards with the operator panel and

with the STARTER software

Easy commissioning based on process values in the language of

the user, even for complex applications, such as cooling towers

or fill levels

4 integrated, freely-programmable PID controllers Distributed closed-loop control for motor-independent process

control without PLC

3 freely-programmable digital time switches Control for freely-selectable daily and weekly programs

Isolated digital inputs with separate

potential group

Insulated analog inputs

Potential transfer avoided

EMC-compliant design without the need for additional com-

ponents in line with process industry requirements

NI1000/PT1000 temperature sensor interface Direct connection of temperature sensors without external

interface unit

230 V relay Direct control for auxiliary equipment,

e.g. reactor or valve actuators

Linear and square torque characteristic for fluid flow and

positive displacement machines

Controller performance tailored to the application

Direct connection of 3 pressure/fill-level sensors Connection of actuators commonly used in the application

without the need for additional components

Integrated software functions

PLC functions for local control tasks

Freely parameterizable PID controllers (mini-PLC functionality)

Flexible deployment of integrated functions

- Savings in additional, external components

Automatic restart function after power failure

Flying restart

Kinetic buffering (Vdc_min control)

Energy saving using the hibernation mode

Load check function to monitor belts and flow

Numerous software functions for flexible implementation

in diverse applications

Cooling concept for increased ruggedness

Push-through variant for selected power modules Heat is conducted outwards, saving space in the

control cabinet

Heat loss is dissipated using an

external heat sink

Electronic modules not located in air duct

Naturally cooled electronics

Consistent convection cooling of the CU

The air only flows through the heat sink

Electronic modules are especially rugged (coated)

Significant increase in the ruggedness

Increased reliability

Ensures independence of environmental effects Significant increase in the service lifetime and usage time

Can even be used under high climatic stress

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SINAMICS G1206

SINAMICS G120

User-friendly design of the SINAMICS G120

Selection of the SINAMICS G120 is reduced to two or three

steps thanks to the modular system used.

User-friendly operation: Intelligent and Basic Operator Panels

The optimum power module can be selected intuitively

based on the motor power required, the connection

voltage and the expected braking cycles.

The optimum Control Unit is selected, based on the

number of I/Os and any additional functions required

such as Safety Integrated or HVAC. The communication

options are already integrated and do not have to be

additionally ordered or plugged in.

Optionally, one of the operator panels described below

can be selected for local operation.

Operator panel IOP (Intelligent Operator Panel) BOP-2 (Basic Operator Panel)

Description

Thanks to the large text display, menu-based operation and

the application wizards, commissioning of the standard

drives is easy.

Integrated application wizards guide the user interactively

through the commissioning process for important appli-

cations such as pumps, fans, compressors and conveyor

systems.

Commissioning of standard drives is easy with the menu-

driven dialog on a 2-line display. Simultaneous display of

the parameter and parameter value, as well as parameter

filtering, means that basic commissioning of a drive can

be performed easily and, in most cases, without a printed

parameter list.

Can be flexibly used It is either directly mounted on the Control Unit,mounted in the door or used as handheld device

(dependent on the inverter type)

It is either directly mounted on the Control Unit or

mounted in the door (dependent on the inverter type)

Quick commissioning

without expert knowledge

Standard commissioning using the clone function

User-defined parameter list with a reduced number of self-selected parameters

Simple commissioning of standard applications using

application-specific Wizards, it is not necessary to knowthe parameter structure

Simple local commissioning on-site using the handheld

version

High degree of operator friendli-

ness and intuitive handling

Direct manual operation of the drive you can toggle between the automatic and manual modes

Graphic display for presenting status values in bar-type

diagrams such as pressure, flowrate

Two-line display for indicating up to 2 process values

with text

Status display with freely selectable units to specify

physical values

Status display of predefined units

Minimization of maintenance

times

Diagnostics using plain text display, without documen-

tation and can be used locally on-site

Simple update of languages, wizards and

firmware via USB

Diagnostics with menu prompting on 7-segment display

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SINAMICS G120 7

Technical data

Control Units P series, optimized for pumps,fans, compressors B series with basic I/O structure E series with standard I/O structureand integrated safety technology

Mounting dimensions (W x H x D)in mm

73 x 199 x 58.4 73 x 199 x 46 73 x 199 x 46

Communication functions

PROFIBUS CU230P-2 DP CU240B-2 DP CU240E-2 DP, CU240E-2 DP-F

RS 485 serial interfaces withModbus RTU and USS protocol

CU230P-2 HVAC CU240B-2 CU240E-2, CU240E-2 F

BACnet MS/TP CU230P-2 HVAC

CANopen CU230P-2 CAN

USB interface 4 4 4Safety functions according to Category 3 of EN 954-1 or according to SIL2 of IEC 61508

Integrated safety functions

STOSTO, SS1, SLS, SDISTO, SS1, SLS, SDI, SSM

CU240E-2, CU240E-2 DP CU240E-2 F CU240E-2 DP-F

Electrical data

Supply voltage 24 V DC(from the Power Module or external)

24 V DC 24 V DC

Digital inputsparameterizable, isolated

6 4 6

Digital inputs, fail-safeparameterizable, isolated

CU240E-2, CU240E-2 DP: 1 CU240E-2 DP-F: 3

Analog inputsparameterizable

2, switchable between -10 to 10 Vand 0/4 to 20 mA,can be used as digital inputs

1, switchable between 0/4 to 20 mAand NI1000/ PT1000

1, NI1000/PT1000

10 to 10 V, 0 to 20 mA and switchablefrom -10 to +10 V

All can be used asadditional digital inputs

20 to 10 V, 0 to 20 mA and switchablefrom -10 to +10 V0 to 10 V and 0 to 20 mA

All can be used as

additional digital inputsDigital outputsparameterizable, isolated

2 (relay CO contact), 250 V AC, 2 A,30 V DC, 5 A

1 (relay NO contact), 30 V DC, 0.5 A

1 (transistor), 30 V DC, 0.5 A 3 (1 x transistor, 2 x relay COcontact), 30 V DC, 0.5 A

Analog outputsparameterizable

2, switchablebetween 0 to 10 V and 0/4 to 20 mA

1, (AO0: 0 to 10 V and 0 to 20 mA) 2, (AO0: 0 to 10 V and 0 to 20 mA,AO1: 0 mA to 20 mA)

Functions

Frequency range that can beskipped

4, programmable

Fixed frequencies 16, programmable

Open-loop/closed-loop controltechnique

Vector (SLVC),V/f(linear, square-law, free, FCC, ECO)

Vector (SLVC),V/f(linear, square-law, free, FCC, ECO), torque control

Operating functions PID controller, hibernation, 3x freelyprogrammable digital time switches,automatic restart, flying restart, slipcompensation, kinetic buffering(only in conjunction with the PM240Power Modules), and many more.

Positioning down ramp, automatic restart, flying restart,slip compensation, jog operation, kinetic buffering,motor temperature monitoring, free function blocks,and many more.

Protective functions Motor temperature monitoring with and without temperature sensor Load duty cycle monitoring, Power Module monitoring, plant/system protectivefunctions

Mechanical data

Degree of protection IP20

Software

STARTER, SIZER, DT Configurator 4 4 4Accessories

IOP, BOP-2 Shield connection plate PC Connection Kit 2 Memory card (MMC or SD)

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The information provided in this brochure contains descriptions

or characteristics of performance which in case of actual use do

not always apply as described or which may change as a result of

further development of the products.

An obligation to provide the respective characteristics shall only

exist if expressly agreed in the terms of contract. Availability and

technical specifications are subject to change without prior no-

tice.

All product designations may be trademarks or product names of

Siemens AG or supplier companies whose use by third parties for

their own purposes could violate the rights of the trademark

Power Modules PM240Braking with braking resistor

PM250Braking with regenerative feedback

PM260Regenerative feedback,long cable lengths

Line supply voltage 3-ph. 380 ... 480 V AC 10 % 3-ph. 500 ... 690 V AC 10% 1)

1) 500 ... 600 V is possible when derated

PowerHO = High OverloadLO = Low Overload

Unfiltered:0.37 ... 200 kW (HO)0.37 ... 250 kW (LO)Filtered:2.2 ... 75 kW (HO)2.2 ... 90 kW (LO)

Unfiltered:15 ... 75 kW (HO)18.5 ... 90 kW (LO)Filtered:5.5 ... 75 kW (HO)7.5 ... 90 kW (LO)

7.5 ... 37 kW (HO)11 ... 55 kW (LO)

Rated input current(dependent on the motorload and line impedance)

PM240 FS A-GX (400 V) unfiltered:1.7 ... 442 APM240 FS B-F (400 V) filtered:7.6 ... 204 A

2.6 ... 145 A 12 ... 46 A

Rated output current(derating for ambient temper-atures > 40 C (LO) or > 50 C(HO))

PM240 FS A-GX (400 V) unfiltered:1.3 ... 370 A (HO)1.3 ... 477 A (LO)PM240 FS B-F (400 V) filtered:1.3 ... 145 A (HO)1.3 ... 178 A (LO)

1.3 ... 145 A (HO)1.7 ... 178 A (LO)

10 ... 42 A (HO)14 ... 62 A (LO)

Mounting dimensions(W x H x D) in mmDepth without Control Unit

Unfiltered (power at LO):A: 0.37 ... 1.5 kW: 73 x 173 x 145B: 2.2 ... 4.0 kW: 153 x 270 x 165C: 7.5 ... 15.0 kW: 189 x 334 x 185D: 18.5 ... 30 kW: 275 x 419 x 204E: 37 ... 45 kW: 275 x 499 x 204F: 55 ... 132 kW: 350 x 634 x 316GX: 160 ... 250 kW: 326 x 1533 x 547

Filtered (power at LO):B: 2.2 ... 4.0 kW: 153 x 270 x 165C: 7.5 ... 15.0 kW: 189 x 334 x 185D: 18.5 ... 30 kW: 275 x 512 x 204E: 37 ... 45 kW: 275 x 635 x 204F: 55 ... 90 kW: 350 x 934 x 316

Unfiltered (power at LO):D: 18.5 ... 30 kW: 275 x 419 x 204E: 37 ... 45 kW: 275 x 499 x 204F: 55 ... 90 kW: 350 x 634 x 316

Filtered (power at LO):C: 7.5 ... 15.5 kW: 189 x 334 x 185D: 18.5 ... 30 kW: 275 x 512 x 204E: 37 ... 45 kW: 275 x 635 x 204F: 55 ... 90 kW: 350 x 934 x 316

Filtered/Unfiltered (power at LO):D: 11.0 ... 18.5 kW: 275 x 455 x 204F: 30 ... 55 kW: 350 x 634 x 316

Electrical data

Line frequency 47 ... 63 Hz

Overload capability(for High Overload)

1.5 x rated current for 1 min within 5 min2.0 x rated current for 3 s within 5 min 2)

2) 90 ... 200 kW - deviations, refer to Catalog D11.1

Overload capability

(for Low Overload)

1.1 x rated current for 1 min within 5 min

1.5 x rated current for 3 s within 5 min3)

3) 110 ... 250 kW - deviations, refer to Catalog D11.1All CUs and PMs in conformance with the standard: CE (Low Voltage Directive 72/23), UL, cUL, c-tick, ISO 9001, Safety Integrated, environmental conditions according to IEC 721-3-2

Output frequency 0 ... 650 Hz (V/fand FCC control types)0 ... 200 Hz (vector control)

0 ... 200 Hz

Pulse frequency 4 kHz (standard) or4 ... 16 kHz (derating)

4 kHz (standard) or4 kHz ... 16 kHz (derating)FS F: 4 kHz (standard) or

4 kHz ... 8 kHz (derating)

16 kHz (standard)

Inverter efficiency 96 ... 97 % 95 ... 97 % 95 ... 97 %

Functions

Braking functions Dynamic brake, DC brakeMotor holding brake, Compound brake

Regenerative feedback in generating operation

Motors that can be connected Three-phase induction and three-phase synchronous motors

Degree of protection IP20

Siemens AG

Industry Sector

Drive Technologies Division

Motion Control Systems

Postfach 3180

91050 Erlangen

GERMANY

Subject to change without prior notice

Order No.: 6ZB5471-0AP02-0BA2

3P.8322.54.08 / Dispo 18404

BR 0711 5.0 SB 8 En

Printed in Germany

Siemens AG 2011

www.siemens.com/drives