Overview
Easy handling, productivity and energy efficiency – Siemens offers an answer to these trends with the SINAMICS G120P series. SINAMICS G120P is an innovative and user-friendly converter series that has been specifically optimized for pump, fan and compressor applications in the industrial environment, but also for tasks in building automation.
SINAMICS G120P offers efficient drive solutions for a wide range of applications. With their easy handling, the drives support the user not only in optimizing existing frequency-controlled drives, but also in converting fixed-speed drives and in retrofitting.
The SINAMICS G120P converter series features advanced hardware and software functions that make a substantial contribution towards saving energy and thus make more careful use of our natural resources.
- SINAMICS G120P in degree of protection IP20, PM230 Power Module, frame size FSB
- SINAMICS G120P in degree of protection IP20, PM240P-2 Power Module, frame size FSD
- SINAMICS G120P in degree of protection IP20, PM330 Power Module, frame size GX
- SINAMICS G120P in degree of protection IP20, PM230 Power Module, frame size FSC Push Through (with Control Unit and BOP‑2 operator panel)
- SINAMICS G120P in degree of protection IP55, PM230 Power Module, frame size FSB
- SINAMICS G120P Cabinet converter cabinet units, versions A and C
User-friendliness
A high degree of user-friendliness is one of the main characteristics of the SINAMICS G120P:
- Operator panel with color display and extensive diagnostics functions (IOP‑2)
- Simple application-specific commissioning wizard “on board” the IOP‑2 (Intelligent Operator Panel)
- Plain text scripts for integration in the STARTER commissioning tool for more demanding applications
- SINAMICS SD card for storing parameter settings, cloning and local commissioning
- Guided operation using wizards
- SINAMICS G120P offers two basic options for guided parameterization/setting in a target application:
Commissioning simple applications
Using application wizards optionally available in the IOP‑2 operator panel 1)
The following wizards are available:
- Basic commissioning
- Pump with/without PID control
- Fan with/without PID control
- Compressor with/without PID control
- PID setting
- Boost setting
An appropriate connection diagram for the standard wiring can be found in the documentation of the IOP‑2 operator panel.
Commissioning of more demanding applications
Using plain text scripts through solution-based dialog prompting in the STARTER commissioning tool
The wizards support setpoint input for process values and setpoint exchanges using timers. They also allow easy integration of technological functions, such as cascade connection or hibernation mode. The connection diagrams for standard wiring that are required for the wizards are also supplied.
The following wizards are available:
- Fan for exhaust air with closed-loop control of pressure/air quality
- Fan for cooling tower with closed-loop control of cooling water temperature
- Fan for stairwell with closed-loop control of pressure and essential service mode
- Fan for tunnel/parking garage with closed-loop control of air quality and essential service mode
- Fan for supply air with closed-loop control of pressure/temperature/air quality/flowrate
- Pumps with closed-loop control of pressure
- Pumps with closed-loop control of level
- Pumps for cooling circuits with closed-loop control of temperature
- Compressor with closed-loop control of pressure
1) More information is available on the Internet at https://support.industry.siemens.com/cs/document/67273266
Benefits
- Energy efficiency
SINAMICS G120P increases the efficiency and minimises energy consumption in the complete process chain. The converter has integrated hardware as well as software functions as standard. The main features are:
- PM230 Power Modules up to 90 kW: Extremely high active power component of apparent power thanks to efficient converter topology. For the same drive power, the converter requires a lower line current than comparable converters
- Flux reduction through automatic adaptation of the motor current to the prevailing load conditions with closed-loop control modes U/f (ECO) and vector without sensor (SLVC) and savings of up to 5 % under partial load conditions
- Hibernation mode dependent on setpoints in the process
- Automatic switchover to line operation is possible at rated speed (bypass mode)
Optimum energy management through innovative technology
Optimised converter topology for PM230 Power Modules
- Compliance with limits for line harmonic distortion in accordance with EN 61000‑3‑12 (RSCE > 250) without a line reactor
- Reduced apparent power as a result of high power factor λ = 0.9
- Smaller cable cross-sections can be used because mains power consumption is reduced
Flux reduction
Energy-saving capability through automatic adaptation of the magnetic flux in the motor to prevailing load conditions (lower motor losses under partial load conditions)
Hibernation mode
Energy-saving capability: The drive is started/stopped in line with the currently applicable setpoints, thereby avoiding excessive mechanical loads
High efficiency
- η ≥ 98 % with PM330 Power Module
- η > 97 % with PM240P-2 Power Module
- η ≤ 97 % with PM230 Power Module
Straightforward, application-specific commissioning and operation using operator panel
- Local commissioning without specialized knowledge of converters using application-specific wizards
- Unique: SINAMICS SD memory card for pre-parameterization and cloning of converter data sets
- Data backup for easy replacement
- USB port integrated on the CU230P‑2 Control Unit for commissioning and easy diagnostics using the STARTER commissioning tool
- Commissioning/diagnostics and controlling of converters
Flexible deployment of integrated functions
- PLC functions for local control tasks
- Flexible use of integrated function blocks → No need for additional, external components
- 4 integrated PID controllers
- Distributed closed-loop control for motor-independent process control without higher-level controller (PLC)
- 3 freely programmable digital timer switches
- Control for freely selectable daily and weekly programs
Flexible deployment across a wide range of applications
- Isolated digital inputs with separate potential group
- Isolated analog inputs
- Potential transfer avoided
- EMC-compliant design without the need for additional components in line with process industry requirements
- Pt1000/LG-Ni1000/DIN-Ni1000 temperature sensor interface
- Direct connection of temperature sensors without external interface unit
- 230 V AC relay
- Direct control for auxiliary equipment, e.g. reactor or valve actuators
- Safety functions
- PM230 Power Modules, frame sizes FSA to FSC: In conjunction with the CU240E-2 Control Unit 1) Control of the STO safety function acc. to SIL 2
- PM240P-2 Power Modules: Terminals for controlling STO and SS1 safety functions acc. to SIL 3
- PM330 Power Modules: Terminals for controlling STO and SS1 safety functions 2) acc. to SIL 2 and SIL 3
- Terminal strip X9 at PM330 Power Module
- Input for external 24 V DC supply
- Input for external alarm/fault
- Input for EMERGENCY OFF/EMERGENCY STOP
- Output for 24 V DC
- Control of the main contactor
- Feedback message “DC link charged”
1) More information on the CU240E‑2 Control Unit is available in Catalog D 31.1, Chapter SINAMICS G120.
2) The safety functions are only available as from function release FS 04 of the PM330 Power Modules.
Flexible, modular system for challenging environmental conditions
- Operation possible at ambient temperatures of up to +60 °C (140 °F)
- Modular design of power and control electronics
- Power range can be easily extended
- Fast exchange of power units
- Removable operator panel for built-in and wall-mounted units
- Protection against unauthorised access
- Degree of protection IP55/UL Type 12 with IOP‑2, BOP‑2 operator panel or blanking cover
- Degree of protection IP20 with IOP‑2 or BOP‑2 operator panel or blanking cover
- Degree of protection IP20 Push Through variant with IOP‑2 or BOP‑2 operator panel or blanking cover
- Replacement of individual components without the need for reinstallation
Application
The specialist for pump, fan and compressor applications.
SINAMICS G120P is ideally suited to pump applications (centrifugal pumps, oscillating and rotating pumps), fan applications (axial and radial fans) and compressor applications (cooling compressors, air and gas compressors). They are deployed in industrial environments, in the process industry and water industry and in building automation.
SINAMICS G120P is ideally suited for the following applications:
- Circulating pumps for heating and cooling systems
- Pumps for pressure boosting stations
- Level control
- Fans in cooling towers
- Fans for air intake and discharge
- Fans for tunnels and multi-storey car parks
- Fans for stairwells
- Compressors for supplying compressed air
Reliable operation in harsh environments
SINAMICS G120P is suitable for use under harsh environmental conditions:
- High degree of protection IP55 for installation outside the control cabinet
- Degree of protection IP20 for use in the control cabinet
- Degree of protection IP20 Push Through variant for space-saving design when installed in the control cabinet; power losses are dissipated using an external heat sink, separate internal air circulation
- Operation possible at ambient temperatures of up to 60 °C (140 °F)
- Coated modules for increased resistance to humidity and dust
Design
SINAMICS G120P is a modular converter system comprising the following components.
- CU230P‑2 Control Unit
- Power Module
- Operator panel or blanking cover
CU230P‑2 Control Unit
The converter communication interface is defined when selecting the Control Unit (FW V4.5 and higher).
- CU230P‑2 HVAC → USS, Modbus RTU, BACnet MS/TP, FLN P1
- CU230P‑2 DP → PROFIBUS
- CU230P‑2 PN → PROFINET, EtherNet/IP
The CU230P-2 Control Unit controls and monitors the Power Module and the connected motor using several different closed-loop control modes that can be selected. It supports communication to a local or central controller as well as to the monitoring equipment, and allows all process-related auxiliary equipment and external components to be connected (sensors, valves, contactors, etc.).
Power Modules
The Power Module is selected depending on the power requirement and the application. State-of-the-art IGBT technology with pulse-width modulation is used for reliable and flexible motor operation. Comprehensive protection functions provide a high degree of protection for the Power Module and the motor.
Power Modules for use in building technology for heating, air conditioning and ventilation applications
The Power Modules in degree of protection IP20 are intended for installation in a control cabinet:
- PM230 with integrated filter class A, 0.37 kW to 75 kW
- PM230 without integrated line filter, 0.37 kW to 75 kW
- PM230 with integrated filter class A, Push Through variant, 3 kW to 18.5 kW
- PM230 without integrated line filter, Push Through variant, 3 kW to 18.5 kW
The Power Modules in degree of protection IP55 can be erected as distributed units outside a control cabinet.
- PM230 with integrated filter class A, degree of protection IP55/UL Type 12, 0.37 kW to 90 kW
- PM230 with integrated filter class B, degree of protection IP55/UL Type 12, 0.37 kW to 90 kW
Power Modules for use in the water/wastewater sector as well as in industrial applications
The Power Modules in degree of protection IP20 are intended for installation in a control cabinet:
Line voltage 380 V to 480 V 3 AC
- PM240P-2 with integrated filter class A, 22 kW to 132 kW
- PM240P-2 without integrated line filter, 22 kW and 132 kW
- PM330 without integrated line filter, 160 kW to 560 kW
Line voltage 500 V to 690 V 3 AC
- PM240P-2 with integrated filter class A, 11 kW to 132 kW
- PM240P-2 without integrated line filter, 11 kW and 132 kW
- PM330 without integrated line filter, 315 kW to 630 kW
SINAMICS G120P Cabinet
SINAMICS G120P units rated for outputs of 75 kW and higher are also available in the control cabinet version SINAMICS G120P Cabinet for line voltages of 380 V to 480 V 3 AC and 500 V to 690 V 3 AC.
- SINAMICS G120P Cabinet, degrees of protection IP20/IP21/IP23/IP43/IP54, 75 kW to 630 kW, with and without line filter
Operator panel or blanking cover
- Intelligent Operator Panel IOP‑2, degree of protection IP55/UL Type 12
- The IOP‑2: supports entry-level personnel and drive experts. Thanks to the color display, menu-based operation and the application wizards, it is easy to commission, diagnose and locally control standard drives. Optionally available wizards 1) interactively guide users through the commissioning process.
- Basic Operator Panel BOP‑2, degree of protection IP55/UL Type 12
- The menu prompting and the 2-line display facilitate fast and user-friendly commissioning of the converter. Simultaneous display of the parameter and parameter value, as well as parameter filtering, means that basic commissioning of a drive can also be performed without a printed parameter list.
- Blanking cover, degree of protection IP55/UL Type 12
- The blanking cover is mounted on the Power Module in place of an operator panel, provided that an operator panel is not required.
The operator panel supports user-friendly local commissioning, control and diagnostics and enables complete converter data sets to be pre-parameterised and cloned.
Note regarding PM230 Power Modules in degree of protection IP55/UL Type 12:
It is essential to plug on an operator panel or the blanking cover in order to achieve degree of protection IP55.
1) Additional information is available on the Internet at https://support.industry.siemens.com/cs/document/67273266
Line-side power components
The following line-side power components are available for the SINAMICS G120P converters:
- Line filters for PM230 and PM330 Power Modules and SINAMICS G120P Cabinet
- With an additional line filter, the Power Module complies with a higher radio interference class.
- Line reactors for PM330 Power Modules and SINAMICS G120P Cabinet
- Line reactors smooth the current drawn by the converter and thus reduce harmonic components in the line current. Through the reduction of the current harmonics, the thermal load on the power components in the rectifier and in the DC link capacitors is reduced as well as the harmonic effects on the supply. The use of a line reactor increases the service life of the converter.
- SINAMICS G120P Cabinet units feature a cabinet-integrated line-side reactor as standard.
Note: A line reactor must not be used in combination with a PM230 Power Module.
Recommended line-side overcurrent protection devices and power components
This section contains recommendations for additional line-side components, such as Siemens fuses and circuit breakers (line-side components must be dimensioned in accordance with IEC standards).
Additional information about the listed fuses and circuit breakers is available in the Catalogs LV 10, IC 10 and IC 10 AO as well as in the Industry Mall.
DC link components
The following DC link components are available for the SINAMICS G120P converters:
- Braking Module for PM330 Power Modules and SINAMICS G120P Cabinet
- A Braking Module and the matching braking resistor are required to achieve controlled braking of a drive. The Braking Module houses the power electronics and the associated control circuit.
- Braking resistors for PM330 Power Modules and SINAMICS G120P Cabinet
- Excess energy in the DC link is dissipated via the braking resistor.
Load-side power components
Various load-side power components are available for the SINAMICS G120P converters. These allow the use of longer shielded motor cables and increase the motor service life:
- Output reactors
- Output reactors reduce the rate of voltage rise (dv/dt) and the height of the current peaks, and enable longer motor cables to be connected.
- Sine-wave filters for PM230 Power Modules
- Sine-wave filters limit the rate of voltage rise (dv/dt) and the peak voltages on the motor winding. Similar to an output reactor, they enable the connection of longer motor cables.
- dv/dt filters plus VPL for PM240P-2 and PM330 Power Modules
- dv/dt filters plus VPL (Voltage Peak Limiter) limit the voltage rate-of-rise dv/dt to values <500 V/μs and the typical voltage peaks to values according to the limit value curve as per IEC/TS 60034‑17: 2006.
- Standard motors with standard insulation and without insulated bearings can be used for converter operation if a dv/dt filter plus VPL is used.
- dv/dt filters compact plus VPL for PM330 Power Modules and SINAMICS G120P Cabinet
- dv/dt filters compact plus VPL (Voltage Peak Limiter) limit the voltage rate-of-rise dv/dt to values of <1600 V/μs and the typical voltage peaks to values according to the limit value curve A to IEC 60034‑25: 2007.
- Standard motors with standard insulation and without insulated bearings can be used for converter operation if a dv/dt filter compact plus VPL is used.
Optional accessories
Line-side cable connection, left, for PM330 Power Modules
Push Through mounting frame for PM230 Power Modules
SINAMICS memory card (SD card)
PC converter connection kit 2
Shield connection kits for CU230P‑2 Control Units (for PM230 and PM240P-2 Power Modules)
Shield connection kits and shield plates for PM230 and PM240P-2 Power Modules
Spare parts
- Spare parts kit for Control Units
- Shield connection kits for PM240P-2 Power Modules
- Shield plates for PM230 Power Modules
- Mounting set for PM230 Power Modules
- Terminal Cover Kit for PM230 Power Modules
- Fan units and replacement fans
Function
Technology function
Functions specific to pumps, fans and compressors are already integrated, e.g.:
- Automatic restart – Application restart after a power failure or fault occurrence
- Flying restart – Connection of the converter when the motor is running
- Flux reduction – Automatic adaptation of the motor current to the prevailing load conditions in U/f control mode (ECO mode) as well as in sensorless vector control mode
- Cascade connection – Load-dependent connection and disconnection of a maximum of three additional motors by the converter in order to provide a largely constant output power (implemented by means of an additional external circuit)
- Hibernation mode – Startup or shutdown of the drive when the relevant value drops below an external setpoint or the internal PID controller setpoint
- Real-time clock – For time-dependent process controls, e.g. to reduce the temperature of a heating control at night and with automatic daylight saving/standard time switchover
- Freely programmable logical function blocks – For simulating simple PLC functions
Functions especially for building technology as well as heating/air conditioning/ventilation applications
- 4 integrated PID controllers – One PID controller for controlling the drive speed as a function of pressure, temperature, flowrate, fill level, air quality and other process variables, and a further three PID controllers with freely configurable outputs, e.g. for controlling valves (heating, cooling) or flaps
- Emergency mode – Special converter operating mode that enhances the availability of the drive system in the event of a fire
- Closed-loop control of a zone with up to 3 sensors for pressure or temperature, or
- Closed-loop control of two independent zones, each with one sensor
- Bypass mode – When the setpoint is reached or a fault occurs, the system changes over to line operation (implemented by means of an additional external circuit)
- Programmable time switches
Configuration
The following electronic configuring guides and engineering tools are available for SINAMICS G120P converters:
SinaSave energy efficiency tool
Use SinaSave to calculate potential energy savings
The web-based tool SinaSave can be used to estimate the potential savings which can be achieved over the entire lifecycle, e.g. for pump and fan applications, thanks to SINAMICS. The tool takes into consideration all important plant-specific quantities, such as the power and load data of the application, the relevant control mode and the operation profile for the application in question. The result delivered by the tool specifies the potential energy savings which can be achieved with the specific application in conjunction with the Integrated Drive System or the drive component. The tool also provides a monetary evaluation of the potential savings and estimates the payback period.
Drive Technology Configurator (DT Configurator)
Drive Technology Configurator (DT Configurator) within the CA 01
The interactive catalog CA 01 – the offline Industry Mall of Siemens on DVD‑ROM – contains over 100 000 products with approximately 5 million possible drive system product variants. The Drive Technology Configurator (DT Configurator) has been developed to facilitate selection of the correct motor and/or converter from the wide spectrum of drives. It is integrated as a selection tool in Catalog CA 01.
Online DT Configurator
In addition, the DT Configurator can be used on the Internet without requiring any installation. The DT Configurator can be found in the Siemens Industry Mall at the following address: http://www.siemens.com/dt-configurator
SIZER for Siemens Drives engineering tool
Configuring made simple and systematic
The SIZER for Siemens Drives engineering tool is used to configure low-voltage drive systems: Using the application as the prime reference, this tool provides step-by-step support in defining the mechanical system and designing converters, motors and gear units. It also helps the user to configure other system components and to design open-loop and closed-loop control functions. In addition to engineering results such as characteristics, technical specifications and installation and dimensional drawings, SIZER for Siemens Drives also provides calculations pertaining to performance and load-dependent power requirements.
SIZER WEB ENGINEERING engineering tool
Drive engineering – flexible, customised and user-friendly
A solution for a drive task can be identified quickly with the web-based tool: menu-prompted workflows guide the user through the technical selection and dimensioning of products and drive systems, including the accessories.
Based on an integrated inquiry functionality, SIZER WEB ENGINEERING also offers you special customized solutions for applications which cannot be addressed using “Standard Products”; i.e. the focus is on flexibility and customized solutions.
Comprehensive documentation, such as data sheets, startup calculations, dimensional drawings, offer documentation and a lot more are integrated in the tool. The result: Customised solutions for any drive task.
The product groups supported are:
- High-voltage motors
- Low-voltage motors
- Medium-voltage converters
- Low-voltage converters
- DC converters
The tool can also be used to design the following drive systems:
- Medium-voltage systems
- Low-voltage systems
- Basic single-axis applications for pumps, fans, and compressors
- Complex applications (on condition that: SIZER for Siemens Drives is installed)
STARTER commissioning tool
Commissioning and diagnostics – intelligent and easy
The STARTER commissioning tool allows menu-prompted commissioning, optimization and diagnostics. Apart from the SINAMICS drives, STARTER is also suitable for MICROMASTER 4 devices.
SINAMICS Startdrive commissioning tool
SINAMICS engineering in the TIA Portal
SINAMICS Startdrive is a tool for configuring, commissioning, and diagnosing the SINAMICS family of drives and is integrated into the TIA Portal. SINAMICS Startdrive can be used to implement drive tasks with the SINAMICS G120, SINAMICS G120C, SINAMICS G110M, SINAMICS G120D and SINAMICS G120P drives. The commissioning tool has been optimized with regard to user-friendliness and consistent use of the TIA Portal benefits of a common working environment for PLC, HMI and drives.
Drive ES engineering system
Drive ES is the engineering system that can be used to integrate the communication, configuration and data management functions of Siemens drive technology into the SIMATIC automation world easily, efficiently and cost-effectively. Two software packages are available for SINAMICS – Drive ES Basic and Drive ES PCS 7.
You can find more information about the Drive ES engineering system in the chapter Engineering Tools.
Additional information about the Drive ES engineering system is available on the internet at http://www.siemens.com/drive-es
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