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Sinamics G120X

SINAMICS G120X infrastructure converters for HVAC/Water/Wastewater


SINAMICS G120X, frame sizes FSA to FSJ, degree of protection IP20, with IOP‑2 Intelligent Operator Panel

Easy handling, utmost reliability, superior efficiency and advanced digitalization – Siemens offers an answer to these trends with the SINAMICS G120X converter series. SINAMICS G120X is an innovative and user-friendly converter series that has been specifically developed for applications performed in infrastructure environments such as water/wastewater, but also for tasks in building automation. In this context, the converter supports, for example, pump, fan and compressor applications through numerous integrated functionalities and combines these in one device for the target sectors.

The SINAMICS G120X converter is an integrated and efficient drive solution for a wide range of tasks. The system allows convenient handling through optimized user interfaces: IOP‑2 Intelligent Operator Panel with graphic color display and the optional web server module SINAMICS G120 Smart Access – a WLAN-based web server solution. Thus, the SINAMICS G120X fulfils the request for an easy and fast setup of the devices during the commissioning phase. Further, experienced users can use the full flexibility of a SINAMICS converter and adjust the relevant application to their requirements.

Totally integrated operation - this approach is also supported from ordering through to delivery. 
For example, all the major features of the converter are configured and displayed in the article number. The delivery includes the complete device - as configured - that means, the converter and the selected operator panel.

In addition, SINAMICS G120X has an extremely rugged and reliable construction. The integrated DC link reactor with a maximum output of 250 kW and optional resistance to harmful gases up to environmental class 3C3 ensure a reliable, stable and largely robust operation.

The converter system is fit for digitalization. Thanks to its full integration in the SINAMICS CONNECT 300 system, data from up to eight converters can be acquired and transferred to the MindSphere cloud solution. The MindSphere application "Analyze MyDrives" facilitates the evaluation of data – tailored to individual customer needs. This simplifies the acquisition and evaluation of converter conditions.

Further, the SINAMICS G120X converter series provides innovative hardware and software functions, e.g. for controlling synchronous reluctance drive systems with SIMOTICS reluctance motors. In this way, the SINAMICS G120X converter series makes a substantial contribution towards saving energy and makes more careful use of our natural resources.

User-friendliness

A high degree of user-friendliness is one of the main characteristics of the SINAMICS G120X:

  • Operator panel with color display and extensive diagnostics functions (IOP‑2 Intelligent Operator Panel)
  • Two different setup options are available: Standard and quick start with graphical user guidance
  • Optimized setups for pumps and fans in the web server module SINAMICS G120 Smart Access
  • SINAMICS SD card for storing parameter settings, cloning and local commissioning
Integrated functionalities for the start/operational/stop phases of the application

SINAMICS G120X is always preset, depending on the selected converter performance. Further, the following functions can be easily selected and parameterized:

Start phase

During the start phase, the following functions are supported by default:

  • Deragging mode for pumps for cleaning the pump system, improving efficiency and reducing wear
  • Pipe filling mode for preventing pressure shocks in pipeline systems
  • Two acceleration ramps for shorter start/stop times
  • Flying restart of the running motor for fast hot restart
  • Automatic restart function after power failure during short downtimes

Operating phase

During the operating phase, the following functions are supported by default:

  • Continued run mode with autonomous reduction of output and pulse frequency
  • PID controller for autonomous closed-loop control mode, operated according to analog input values
  • Up to 16 variable-speed setpoints as fixed frequencies
  • Speed monitoring via sensor (pulse input)
  • Multi-pump control of up to four pumps
  • Protection against blocking, leakage, dry running and cavitation
  • Fire response mode for extended operation in case of emergency
  • Skip frequencies for skipping critical frequencies and avoiding vibration
  • Real time clock for switching over setpoints or controlling releases

Stop phase

During the stop phase, the following functions are supported by default:

  • STO (Safe Torque Off) according to IEC 61508 SIL 3 and EN ISO 13489‑1 PL e and Category 3
    External components (e.g. safety relays) are necessary for using the STO safety function.
  • ON/OFF2 for a optimized braking ramp
  • Condensation protection for the motor
  • Frost protection function for the pump

A detailed description of the functions and connection diagrams are included in the device documentation.

Commissioning of complex applications

Sample applications, which include the description and device setting, are provided for SINAMICS G120X.

The following application descriptions are available:

  • Fan for exhaust air with closed-loop control of pressure and air quality
  • Fan for cooling tower with closed-loop control of the cooling water temperature
  • 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 and flowrate
  • Pumps with closed-loop control of the pressure
  • Pumps with closed-loop control of the filling level
  • Pumps for cooling circuits with closed-loop control of the temperature
  • Compressor with closed-loop control of the pressure
  • Vacuum pump with closed-loop control of the pressure

Practical application examples and descriptions are available on the Internet at
http://www.siemens.com/sinamics-applications

 

Benefits

Energy efficiency

SINAMICS G120X increases the efficiency and minimizes energy consumption in the complete process chain. The converter has integrated hardware as well as software functions as standard. The main features are:

  • Power units with DC link reactor for extremely high active power component 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 V/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
  • High efficiency η ≥ 98 %
Application-specific commissioning and operation using operator panel
  • Local commissioning without specialized knowledge of converters thanks to default settings and graphical user interface
  • Unique: SINAMICS SD memory card for pre-parameterization and cloning of converter data sets
  • Data backup for easy replacement
  • Commissioning/diagnostics and controlling of converters
Flexible deployment of integrated functions
  • Four integrated PID controllers
    Distributed closed-loop control for motor-independent process control without higher-level controller (PLC)
  • Three 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
  • Direct connection of Pt1000/Ni1000 temperature sensors with optional SINAMICS G120X I/O Extension Module (available soon)
  • 230 V AC relay
    • Direct control for auxiliary equipment, e.g. reactor or valve actuators
  • Safety functions
    • Terminals for controlling the STO (Safe Torque Off) Safety function according to IEC 61508 SIL 3 and EN ISO 13489‑1 PL e and Category 3
      External components (e.g. safety relays) are necessary for using the STO safety function.
      For further information see the operating instructions
      http://www.siemens.com/sinamics-g120x/documentation
  • X9 terminal strip for devices in frame sizes FSH and FSJ (315 kW to 630 kW)
    • 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"
  • Use at ambient temperatures of -20 °C to +55 °C possible with PROFINET version (up to +60 °C with other versions available soon)
  • Removable operator panel
    • Protection against unauthorized access
    • Color-coded signaling of operating states
  • Replacement of individual components without the need for reinstallation
    • Plug-in version of control terminals (for replacement without removing wiring)
  • Version for harsh environmental conditions
    • Coated modules for increased resistance to humidity and dust (Class 3C2)
    • PCB coating for environmental class/harmful chemical substances Class 3C3 acc. to EN 60721‑3‑3 (available soon)
Extended warranty

Siemens offers for SINAMICS G120X an extended warranty up to 7½ years:

  • 24 months of standard warranty
  • Optional extension via Drive Service Extended Exchange

More information at:
https://support.industry.siemens.com/cs/ww/en/sc/4842

 

Application

The specialist for pump, fan and compressor applications

SINAMICS G120X 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 the water/waste water industries, in industrial environments, and in building automation.

SINAMICS G120X 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-story car parks
  • Fans for stairwells
  • Compressors for cooling units
Reliable operation in harsh environments

SINAMICS G120X is suitable for use under harsh environmental conditions:

  • Degree of protection IP20/UL Open Type for use in the control cabinet
  • Degree of protection IP21 with optional IP21 top cover for use in lockable control rooms, including outside a control cabinet (available soon)
  • Degree of protection IP20 with optional push-through mounting frame for space-saving design when installed in the control cabinet; power losses are dissipated using an external heat sink, separate internal air circulation (available soon)
  • Use at ambient temperatures of -20 °C to +55 °C possible with PROFINET version (up to +60 °C with other versions available soon)
  • Coated modules for increased resistance to humidity and dust (Class 3C2)
  • Optional for environmental class/harmful chemical substances Class 3C3 acc. to EN 60721‑3‑3 (available soon)
 

Design

((Graphic available soon))

SINAMICS G120X is a converter system that comprises a power output module and a control module with or without an operator panel.

The converter is configured on the basis of 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 converter and motor.

The SINAMICS G120X converters in degree of protection IP20 are intended for installation in a control cabinet.

  • Selection of the line filter for line voltage 380 V to 480 V 3 AC
    • Without integrated line filter, 0.75 kW to 132 kW
    • With integrated line filter Category C2, 0.75 kW to 250 kW
    • With integrated line filter Category C3, 160 kW to 560 kW
    • With additional line filter Category C1 for unfiltered devices, 0.75 kW to 110 kW (available soon)
    • With additional line filter Category C2 for filtered devices, 315 kW to 560 kW
  • Selection of the line filter for line voltage 500 V to 690 V 3 AC
    • Without integrated line filter, 3 kW to 132 kW
    • With integrated line filter Category C2, 3 kW to 55 kW
    • With integrated line filter Category C3, 75 kW to 630 kW
    • With additional line filter Category C2 for filtered devices, 315 kW to 630 kW
  • Environmental class/harmful chemical substances acc. to EN 60721‑3‑3
    • Class 3C2
    • Class 3C3 (available soon)
  • Selection of communication
    • PROFINET, EtherNet/IP
    • PROFIBUS (available soon)
    • USS, Modbus RTU, BACnet MS/TP (available soon)
  • Selection of the operator panel
    The operator panels support user-friendly local commissioning, control and diagnostics and enable complete converter data sets to be pre-parameterized and cloned.
    • Without operator panel
    • BOP‑2 Basic Operator Panel
      The menu prompting and the 2-line display allow for simple 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.
    • IOP‑2 Intelligent Operator Panel
      Supports entry-level personnel as well as drive experts. Thanks to the color display, a user-friendly menu structure and wizards, it is much easier to commission, diagnose and locally control standard drives.
Line-side power components

The following line-side power components are available for the SINAMICS G120X converters:

  • Line filters for categories C1, C2 and C3, see above
    With an additional line filter, the converter complies with a higher radio interference class.
  • Line reactors for devices from 315 kW and for frame sizes FSH and FSJ
    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 G120X frame sizes FSA to FSG feature an integrated DC link reactor as standard. The use of an additional line reactor is not necessary for this.

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.

Load-side power components

Various load-side power components are available for the SINAMICS G120X converters. These allow the use of longer shielded motor cables and increase the motor service life:

  • Sine-wave filters for frame sizes FSA to FSF (available soon)
    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 frame sizes FSD to FSG
    dv/dt filters plus VPL (Voltage Peak Limiter) limit the voltage rate-of-rise dv/dt to values of <500 V/μs and the typical voltage peaks to values according to the limit value curve according to 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 frame sizes FSH and FSJ
    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
  • SINAMICS memory card (SD card)
  • SINAMICS G120 Smart Access for simple setup via Wi‑Fi
  • Push-through mounting frame for frame sizes FSA to FSG (available soon)
  • Increase in degree of protection to IP21 with IP21 top covers for frame sizes FSA to FSG (available soon)
  • Installation kit for line-side cable connection, left, for frame size FSH
  • SINAMICS CONNECT 300 for connecting up to eight converters to the MindSphere cloud (available soon)

Note:

Shield connection kits are an integral component of the delivery.

Spare parts
  • FPI (freely programmable interface) board for frame sizes FSH and FSJ (available soon)
  • PSB (power supply board) board for frame sizes FSH and FSJ (available soon)
  • Current transformers for frame sizes FSH and FSJ (available soon)
  • Spare parts kit for Control Unit for frame sizes FSA and FSJ (available soon)
  • Shield connection kit for Control Unit for frame sizes FSD to FSG (available soon)
  • Shield connection kits for Power Module for frame sizes FSD to FSG (available soon for frame sizes FSA to FSC)
  • Mounting set for frame sizes FSD to FSG
  • Terminal cover kits for covering the connecting terminals for frame sizes FSD to FSG
  • Fan units
    • External for frame sizes FSD to FSJ (available soon for frame sizes FSA to FSC)
    • Internal for frame sizes FSH and FSJ (available soon)
 

Function

Technology function

Functions specific to pumps, fans and compressors are already integrated, e.g.:

  • Specific firmware functions such as deragging or pipe fill mode
  • 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 V/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

Functions especially for building technology as well as heating/air conditioning/ventilation applications

  • Four 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; 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
  • 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
 

Integration

((Graphic))

 

Configuration

The following electronic configuring guides and engineering tools are available for SINAMICS G120X converters:

SINAMICS SELECTOR app (available soon)

Mobile selection guide for frequency converters

Siemens has developed the SINAMICS SELECTOR app as a practical tool for finding article numbers for your SINAMICS converters in the power range from 0.12 kW to 630 kW quickly and easily. Whether for SINAMICS V20, SINAMICS G120C, SINAMICS G120X (available soon) or SINAMICS G120: The app will provide you with the correct article numbers conveniently.

How does it work? Simply select your application, the frequency converter you require, the rated power and device options as well as the necessary accessories.

Then you can save your selection and send it by email. Your preselection is the basis for an order specification with the dealer/Siemens.

You will find the free downloads for Android and for iOS at the following link: 
http://www.siemens.com/sinamics-selector

SINAMICS ASSISTANT app

The error code function of the SINAMICS ASSISTANT app helps you to identify and rectify errors. Just enter the error code of your frequency converter and the app shows you what sort of error it is and how you can rectify it.

This app also recalculates for you the frequency (Hz) of a frequency converter into the speed to be set on the motor (rpm) or vice versa.

In addition, this app offers you a support page on which you can get in touch straight away with the right contact person in your region if you hav

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