SINAMICS G120D distributed converters

The SINAMICS G120D distributed converters are the solution for demanding drive tasks especially in the field of conveyor systems. SINAMICS G120D converters continuously control the speed of three-phase asynchronous (induction) motors and fulfill all the requirements of conveyor system applications from simple frequency control through to demanding vector control and positioning requirements. With its intelligent modular design with IP65 degree of protection, it can be seamlessly integrated into the plant or system and supports a high plant availability and low stocks of spare parts. The innovative power unit concept capable of energy recovery helps save energy. The patented implementation concept of the Safety Integrated Functions is unique worldwide and has been extended further, without the use of external components. This drive can be optimally integrated into the Siemens TIA world of automation via PROFIBUS or PROFINET / EtherNet/IP.

With different device versions (frame sizes FSA to FSC) in a power range from 0.75 kW to 7.5 kW, it is suitable for a wide variety of drive solutions.

Example: SINAMICS G120D, frame size FSA, comprising PM250D Power Module and fail-safe CU250D-2 PN-F Control Unit

Reasons for using distributed drive systems

• Modular drive solutions – therefore standardized mechatronic elements that can be individually tested
• A control cabinet is not required, resulting in a smaller space requirement and lower cooling requirements
• Long motor cables between converter and motor are not required
  • Less power losses
  • Reduced noise radiation
  • Reduced costs for shielded cables
  • No additional filters
• Distributed configurations offer considerable benefits for conveyor systems with their extensive coverage (e.g. in the automotive and logistics sectors)
• Perfectly prepared for digitalization thanks to different communication interfaces and integration via Industrial Edge or in the cloud, e.g. with the Drivetrain Analyzer application

Siemens family of distributed drives

Siemens offers an innovative portfolio of frequency converters to optimally implement distributed drive solutions. The strengths of the individual members of the drive family permit simple adaptation to the widest range of application demands:

• Identical connection systems
• User-friendly commissioning and configuration tools

Products from the family of distributed drives:

• SINAMICS G115D distributed converters
• SINAMICS G120D frequency converters
• SIMATIC ET 200pro FC-2 frequency converters
• SIRIUS M200D motor starters

Modularity

SINAMICS G120D is a modular converter system with IP65 degree of protection comprising various function units. The main units are

• 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. The digital inputs, analog inputs and digital outputs on the device support the simple wiring of sensors and actuators directly at the drive. The input signals can either be directly linked within the Control Unit and initiate local responses independently or they can be transferred to the central control via PROFIBUS or PROFINET / EtherNet/IP for further processing within the context of the overall plant.

The Power Module supplies the motor in a power range from 0.75 kW to 7.5 kW. The Power Module is controlled by a microprocessor in the Control Unit. State-of-the-art IGBT technology with pulse-width-modulation is used for highly reliable and flexible motor operation. Comprehensive protection functions provide a high degree of protection for the Power Module and the motor. The unusually low profile mechanical design is optimized so that the device can be directly used in the plant or system. The Power Module also has the same drilling dimensions for all power ratings (standard footprint). Further, the dimensions are identical to those of SINAMICS G110D. This significantly simplifies the mechanical design, installation and retrofit of a system.

The latest technical documentation (catalogs, dimension drawings, certificates, manuals and operating instructions) is available on the internet at the following address: 
www.siemens.com/sinamics-g120d/documentation

and in the Siemens Product Configurator: 
www.siemens.com/spc

Safety Integrated

The SINAMICS G120D distributed converters include versions for safety-oriented applications. All Power Modules are already designed for Safety Integrated.

The Safety Integrated Function "Safe Torque Off" (STO) (certified according to IEC 61508 SIL 2, ISO 13849-1 PL d and Category 3) is already integrated into the standard versions of the CU240D-2 series (CU240D-2 DP and CU240D-2 PN). It can be activated either over PROFIsafe or over the safety input.

With the fail-safe variants of the CU240D-2 series (CU240D-2 DP-F xx and CU240D-2 PN-F xx) and with the entire CU250D-2 series, the fail-safe SINAMICS G120D converter provides five safety functions which are certified according to IEC 61508 SIL 2, ISO 13849-1 PL d and Category 3:

• 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 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 is operating below a specific speed/feed velocity.

These functions can be activated by means of PROFIsafe or via the safety inputs. A safety output is provided in addition.

All safety functions can be implemented without having to use a motor encoder; the implementation costs are minimal. 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 converter is switched off. They are therefore not permitted for applications involving pull-through loads such as hoisting gear and unwinders.

Efficient Infeed Technology

The innovative Efficient Infeed Technology is employed in PM250D Power Modules. This technology allows the energy produced by motors operating in generator mode connected to standard converters to be fed back into the supply system. At the same time, considerable savings can be achieved in terms of energy consumption and operating costs.

STARTER commissioning tool

The STARTER commissioning tool (V4.3 and higher) supports the commissioning and maintenance of SINAMICS G120D converters. The operator guidance combined with comprehensive, user-friendly functions for the relevant drive solution allow you to commission the device quickly and easily.

SINAMICS Startdrive commissioning tool

SINAMICS Startdrive is a tool integrated into the TIA Portal for configuring, commissioning and diagnostics of the SINAMICS converter family. SINAMICS Startdrive can be used for implementing converter tasks with most of the SINAMICS G and SINAMICS S converter series.

Drive dimensioning of the SINAMICS G115D distributed drive system with the TIA Selection Tool

The SINAMICS G120D distributed drive system is easily configured with the TIA Selection Tool under the drive dimensioning plug-in. It provides support when selecting the hardware and firmware components necessary to implement a drive task. The plug-in encompasses the configuration of the entire drive system and allows the handling of individual drives.

• Mechanical design, installation and retrofit of systems are significantly simplified as a result of the compact and space-saving design with an extremely low profile and with the same drilling dimensions for all power ratings.
• Wide power range from 0.75 kW to 7.5 kW
• The safety functions make it easier to integrate drives into safety-oriented machines or plants
• 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 line supply system. This feedback capability provides enormous potential for energy saving because generated energy no longer has to be converted into heat in a braking resistor. Braking resistors and reactors are not necessary - this is a particular advantage in terms of the project engineering outlay, space requirement and installation costs for the high IP65 degree of protection
• Easy commissioning and maintenance via a fieldbus or point-to-point via a mini USB parameterization interface and screen-based parameterization software and wizards
• The same, standardized plug-in connections for the bus, power and I/O connections (ISO 23570) for the complete range of power ratings of SINAMICS G115D, SINAMICS G120D and SIRIUS M200D (motor starter)
• Integrated positioning functionality supports process-related implementation of positioning tasks with a high dynamic response. Positioning can be implemented with an incremental (HTL) or absolute encoder (SSI)
• Increased degree of ruggedness and longer service life as the electronic modules are coated
• Flexibility due to modularity for a future-oriented distributed drive concept with a high IP65 degree of protection
  • The modules can be easily replaced, which makes the system extremely service friendly.
• Simple, standard implementation of completely distributed plant and system concepts by using products in a scalable fashion:
  • SIRIUS M200D (motor starter)
  • SIMATIC ET 200pro FC-2 (converter for the distributed SIMATIC ET 200pro I/O system)
  • SINAMICS G115D distributed converters
  • SINAMICS G120D (converter for demanding, conveyor-related applications)
• Communications-capable via PROFINET / EtherNet/IP or PROFIBUS with PROFIdrive profile 4.1:
  PROFINET features:
  • Neighbor recognition (LLDP)
  • Ring topology possible (MRP (Media redundancy protocol), MRPD (media redundancy with planned duplication)
  • Isochronous real-time communication (IRT)
  • PROFIenergy
  • PROFIsafe
  • Diagnostics, interrupts
  • Shared Device
  • Attenuation meter (for FO variant)
• Integrated fiber-optic interfaces (with CU240D-2 PN-F FO and CU250D-2 PN-F FO) for use in environments with harsh EMC conditions. These help to maintain stable communication and allow preventive maintenance of the connected PROFINET communication cable by means of an integrated attenuation meter.
• Simple connection, engineering, data management as well as control of the converter in sophisticated plants and systems as a result of the consequential integration in TIA (Totally Integrated Automation)
• High degree of operator friendliness by using the Intelligent Operator Panel (IOP-2) to parameterize, diagnose, control (open-loop) and copy drive parameters
• The ability to connect up to 6 sensors and up to 2 actuators to the Control Unit directly ensures that almost all the information relevant to the drive can be managed directly. Fail-safe Control Units can process signals from up to three fail-safe sensors and one fail-safe actuator. The CU240D-2 Control Units are also equipped with two analog inputs, which can also be used as digital inputs. Local pre-processing of the signals relieves the fieldbus of the task and ensures a faster and more reproducible response time
• Integrated EMC filter class A (acc. to EN 55011)
• Integrated brake control, supported brake voltage 180 V DC (at line voltage of 400 V AC – otherwise U_line × 0.45 = brake voltage)
• Integrated motor protection using a thermal motor model and evaluation of PTC, KTY, bimetal or Pt1000 temperature sensors
• Software parameters for simple adaptation to 50 Hz or 60 Hz motors (IEC or NEMA motors)
• Easy replacement of devices and time-saving copying of parameters to optional memory card
• Engineering and commissioning with standard engineering tools such as SIZER for Siemens Drives (V2.9 and higher), DriveSim Designer (firmware V4.7 SP13 and higher), STARTER (V4.3 and higher), SINAMICS Startdrive, TIA Selection Tool and Drive ES: ensure fast engineering and easy commissioning – STARTER is integrated in STEP 7 with Drive ES Basic with all the advantages of central data storage and totally integrated communication
• Certified worldwide for compliance with CE, UKCA, UL, cUL, RCM and Safety Integrated according to IEC 61508 SIL 2 and ISO 13849-1 PL d and Category 3

The SINAMICS G120D distributed converters are modular converters for standard drives. Each SINAMICS G120D comprises two operative units – a Power Module and a Control Unit.

PM250D Power Module with line supply and motor connections and CU240D-2 Control Unit

Power Modules

The following PM250D Power Modules are available for the SINAMICS G120D distributed converters:

PM250D Power Modules

PM250D Power Modules (0.75 kW to 7.5 kW) have an innovative circuit design which allows line-commutated energy recovery back into the line supply. This innovative circuit permits generated energy to be fed back into the supply system and therefore saves energy.

Control Units

A Control Unit performs closed-loop control functions for the converter. In addition to the closed-loop control, it has additional functions that can be adapted to the particular application through parameterization.

The following Control Units are available for SINAMICS G120D distributed converters:

CU240D‑2 Control Units

The CU240D‑2 Control Units can be used to implement applications with speed/torque control. Several Control Units are available in different versions:

• CU240D‑2 DP → PROFIBUS
• CU240D‑2 DP‑F → PROFIBUS fail-safe
• CU240D‑2 PN → PROFINET
• CU240D‑2 PN‑F → PROFINET fail-safe
• CU240D‑2 PN‑F PP → PROFINET fail-safe Push Pull
• CU240D‑2 PN‑F FO → PROFINET Fail-safe fiber optic

CU250D‑2 Control Units

CU250D‑2 Control Units can be used to implement applications with positioning requirements in the drive. Several Control Units are available in different versions:

• CU250D‑2 DP‑F → PROFIBUS fail-safe
• CU250D‑2 PN‑F → PROFINET fail-safe
• CU250D‑2 PN‑F PP → PROFINET fail-safe Push Pull
• CU250D‑2 PN‑F FO → PROFINET fail-safe fiber optic

Supplementary system components

IOP-2 Handheld Intelligent Operator Panel

The IOP‑2 Handheld supports both newcomers and drive experts. Thanks to the large plain text display, the menu-based operation and the application wizards, it is easy to commission, diagnose and locally control standard drives.

Memory card

The parameter settings for a converter can be stored on the SINAMICS SD memory card. When service is required, e.g. after the converter has been replaced and the data have been downloaded from the memory card, the drive system is immediately ready for use again. The associated slot is located on the rear of the Control Unit.

Mini USB interface cable for communication with a PC

For controlling and commissioning a converter directly from a PC if the appropriate software (STARTER commissioning tool V4.3 and higher or SINAMICS Startdrive) has been installed.

Connecting cables for the Control Units

Flexible plug-in cables to transfer data between the Industrial Ethernet stations or PROFIBUS stations, as well as to supply power to the Control Unit.

Connecting cables for the Power Modules

Connector sets to connect to the line supply and the outgoing motor feeder are available as accessories as well as pre-assembled motor cables for connection to the motor.

Spare parts kit

A spare parts kit is available which comprises small parts such as seals, caps, PROFIBUS address windows and screws.

Replacement fan

A replacement fan is available, which comprises a pre-mounted unit with cover, fan and screws.

The following electronic configuring aids and engineering tools are available for the SINAMICS G120D distributed converters:

DriveSim Designer (firmware V4.7 SP13 or higher)

DriveSim Designer provides easy-to-use models for PROFIdrive-enabled SINAMICS converters, so you can create a digital twin of your drive.

More information is provided on the internet at:
www.siemens.com/drive-virtualization

Siemens Product Configurator

The Siemens Product Configurator helps you to configure the optimum drive technology products for a number of applications – starting with gearboxes, motors, converters as well as the associated options and components and ending with controllers, software licenses and connection systems. The Siemens Product Configurator can be used on the internet without requiring any installation. The Siemens Product Configurator can be found in SiePortal at the following address:
www.siemens.com/spc

SIMARIS planning tools for plants with SINAMICS drives

Electrical planning: Even easier with software!

Electrical planning for power distribution in non-residential and industrial buildings has never been more complex. To ensure you, as a specialist planner, have the best hand when it comes to electrical planning with SINAMICS drives, we provide support with the following efficient software tools: SIMARIS design for dimensioning and SIMARIS project for calculating the space requirements of the distribution boards.

SIZER for Siemens Drives (integrated in the TIA Selection Tool) engineering tool.

The PC-based SIZER for Siemens Drives engineering tool makes it easy to configure the SINAMICS drive family. It provides support when selecting the hardware and firmware components necessary to implement a drive task. SIZER for Siemens Drives supports the complete configuration of the drive system, from basic single drives to demanding multi-axis applications.

The SIZER for Siemens Drives engineering tool is available free on the internet at: 
www.siemens.com/sizer

STARTER commissioning tool

The STARTER commissioning tool allows menu-prompted commissioning, optimization and diagnostics and the TIA functionality. Apart from the SINAMICS drives, STARTER is also suitable for MICROMASTER 4 devices.

The CU240D-2 PN-F FO and CU250D-2 PN-F FO Control Units can be commissioned with STARTER V4.4 and higher.

More information about the STARTER commissioning tool is available on the internet at 
www.siemens.com/starter

SINAMICS Startdrive commissioning tool (for SINAMICS G120D from V13)

SINAMICS Startdrive is a tool integrated into the TIA Portal for configuring, commissioning and diagnostics of the SINAMICS converter family. SINAMICS Startdrive (for SINAMICS G120D from V13) can be used for implementing converter tasks with most of the SINAMICS G and SINAMICS S converter series. The commissioning tool has been optimized in terms of simplicity, ease of use, and consistent use of the benefits of the TIA Portal to provide a uniform working environment for PLC, HMI and drives.

The SINAMICS Startdrive commissioning tool is available for free on the internet at:
www.siemens.com/startdrive

Drive dimensioning of the SINAMICS G120D distributed converter with the TIA Selection Tool

The SINAMICS G120D distributed converter is easily configured with the TIA Selection Tool under the drive dimensioning plug-in. It provides support when selecting the hardware and firmware components necessary to implement a drive task. The plug-in encompasses the configuration of the entire drive system and allows the handling of individual drives.

• Intuitive user interface, menu-based operation and help
• Configuration of the SINAMICS G120D distributed converter
• Adjustable load cycles and various mechanical systems integrated
• Interface to the TIA Portal and SiePortal

The TIA Selection Tool is available for free on the internet at 
www.siemens.com/tia-selection-tool-standalone

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. The Drive ES PCS software package is available for SINAMICS.

More information about the Drive ES engineering system is available on the internet at 
www.siemens.com/drive-es

Unless explicitly specified otherwise, the following technical specifications are valid for all the following SINAMICS G120D distributed converter components listed here.

¹⁾ In product packaging.

²⁾ With shielded motor cable up to 15 m (49 ft).