SINAMICS G120X/XA

Master the Elements

Unrestricted © Siemens AG 2018 [Link]/sinamics-g120x

Confidential © Siemens AG 2018

Agenda

1 Product introduction

2 System Overview

3 Pump and Fan control Functions

5 Selection and Commissioning

4 Technical Details

Confidential © Siemens AG 2018

Page 2
SINAMICS G120X/XA
“Seamless Pump & Fan drive for the Infrastructure market”

The new SINAMICS G120X/XA System is developed with

enhanced features for the water industry and HVAC
applications in the midrange segment.

The G120X/XA offers wide power range from 0.75 to

G120X
630 kW / 1 to 700HP with seamless voltage classes and
protection degrees

The optimum solution due to its out-of-the-box concept,

fast setup time and extremely simple operation

Confidential © Siemens AG 2018

Page 3
The SINAMICS G120X differentiates itself from the
G120 (P) with dedicated features and improvements

SINAMICS
Long cable
lengths
DC-Link choke
G120X/XA Extension module 2nd
increases
flexibility
3C3
coating1
Improvements
Firmware: dedicated over the IP55 service 2nd -20-45 (..60)°C
Optimized I/O Operating
P&F features SINAMICS G120P switch
temperature

SINAMICS G120X

Confidential © Siemens AG 2018

1 in preparation
2nd Available during 2019
Page 4
SINAMICS drive position within the
“Continuous Motion” portfolio

Basic Midrange High-End

SINAMICS SINAMICS SINAMICS

V20 G120X/XA G120
HVAC , 0.12 – 30 kW 0.75 – 630 kW 0.55 – 250 kW
W&WW,
Standard Fan Basic, cost-effective, easy-to- Blocksize compact drive with The modular application -
& Pump operate compact drive (1/3 AC) FW and usability approach specific drive system for
designed to fulfill pump & fan general plant and machinery
needs construction

SINAMICS SINAMICS SINAMICS

V20 G120C G120
Machinery/ 0.12 – 30 kW 0.37 – 132 kW 0.37 – 250 kW
Industry
Constant Basic, cost-effective, easy-to- The compact, cost-effective The modular application -
torque control operate compact drive (1/3 AC) and with optimized functions specific drive system for
drive system general plant and machinery
construction

Confidential © Siemens AG 2018

page 5
 The specialized solution for midrange
W/WW & HVAC applications

Pumps Fans / building auto. Chillers

HVAC

• Pump operation on • Centrifugal / axial fan operation for • Operation of chillers on

- Heating systems, - Air handling units, roof top units - Air conditioning systems and
- Water supply of buildings
- Pressure booster stations - Air exhaust systems, tunnels, garages - Refrigeration technology
- Cooling water systems - Refrigeration

Secondary
Pumps Blowers
processes
Water/WW

• Radial and axial pump operation in • Efficient operation and control of blowers • Pump & fan systems to support
water segments: supply, treatment, e.g. to control the oxygen level in WW industrial processes such as boiler feed
water, ventilation, saltwater injection,
wastewater, transfer and irrigation, well treatment processes dust collection, water transfer, fume
pumps, centrifugal pumps, …. control, water supply, etc.

Confidential © Siemens AG 2018

Page 6
Agenda

1 Product introduction

2 System Overview

3 Pump and Fan control Functions

5 Selection and Commissioning

4 Technical Details

Confidential © Siemens AG 2018

Page 7
The G120XA offers different protection degrees with a
seamless system approach up to 560 kW / 700HP

Operator Wi-Fi Options

H Panel Webserver

G
IP20 F
Power: E
D
0.75 – 400 kW C or
incl.
Power range AB
Voltage / Power kW up to…
Range SD card
IOP-2/ BOP-2 SAM
Choke
3AC380 – 440V
(0.75 – 560 kW ) Wall mounted

du/dt filter

IP00
Power:
450-560 kW or
Power range incl.
kW up to…

Confidential © Siemens AG 2018

Page 8
The G120X offers different protection degrees with a
seamless system approach up to 630 kW / 700HP

Chassis Operator Wi-Fi Options

H J Panel Webserver
IP20 /IP21 kit2,3/
G SD card
IP20 Push Through F
kit3 E
Voltage / Power
UL open type D IP21 roof
Range
Power: C
incl.
or 2nd step
top kit
Power range AB
0.75 – 560 kW kW up to…
3AC200 – 230V1
IP20 / UL open
2nd– 55
(0.75 step
kW /
IOP-2/ BOP-2 SAM push through kit
1 – 75 HP)

I/O ext. module1

3AC380 – 480V 2nd step I/O
(0.75 – 560 kW ) (IP21 UL-type 1)1
Filter B
Power:
3AC500 – 690V 0.75 – 132 kW
(3 – 630 kW ) E F Passive
C D or THDi
A B incl. harmonic filter
(IP55 UL-type 12)1 Power range
<5%
Power: kW up to… 2nd step
0.75 – 132 kW Choke

Sinus filter
du/dt filter

1 Available
on 12/2019 3 IP21 kit/ IP20 PT-kit FS A-G as an orderable option SAM: Smart Access Module
Confidential © Siemens AG 2018 2 Wall mounted w/o cabinet in lockable electrical room IOP: Intelligent Operator Panel
Page 9
Agenda

1 Product introduction

2 System Overview

3 Pump and Fan control Functions

5 Selection and Commissioning

4 Technical Details

Confidential © Siemens AG 2018

Page 10
SINAMICS G120X/XA brings the best pump and fan control
ensuring energy-saving and protection

Pump & Fan Control Features Energy Saving Features Protection Features
Blocking, leakage, dry-running
Deragging Pipe Filling Economy mode protection

Rotation monitoring w. sensor

Multi-pump Dual Ramp
Reluctance Synchronous Motor
control Time Condensation & Frost protection

Flying Keep Running Mode

Auto Restart Energy / flow calculator
Restart
STO
Real Time SIL 3
Timer switch Hibernation
clock
Fire mode
Skip
PID Bypass Mode
Frequency Cavitation protection

Confidential © Siemens AG 2018 Fan & Pump control Energy saving Protection
Page 11
PFC features

Pump & Fan Control Features

Deragging Pipe Filling

G120X Multi-pump
G120X
Software Auto Restart Software
control
features features
Flying Skip
Restart Frequency

Fan control Real Time

Timer switch
Pump control
clock

Dual Ramp
PID
Time

Confidential © Siemens AG 2018

Page 12
Multi-pump control ensures smooth start and stop of every
pump for best performance of the water supply system

Feature/ Function

3AC
Allows the of use several smaller pumps, which
can be switched in and out as required, instead of
one large pump
Control up to 4 pumps by integrated PID
controller, using:

• Pump Switch in /Switch Out

• Pump switchover
• Stop mode
• Service mode

Confidential © Siemens AG 2018

Page 13
 Multi-pump control
Pump switchover

Feature / Function
With pump switchover enabled, the inverter
3AC
monitors the operation status of all running
pumps:
1) If the continuous operating hours of the pump
in inverter operation exceed the threshold,
the inverter switches off the pump and then
switches in an idle pump to keep constant
output power
2) If the continuous operating hours of a pump in
line operation exceed the threshold, the
10 hours 10 hours 10 hours 10 hours inverter first switches off the pump, switches
Pump1 Pump2 Pump3
out the inverter-controlled pump to line
Pump4
operation, and then switches in an idle
pump to run in inverter operation to keep
constant output power

Confidential © Siemens AG 2018

Page 14
Multi-pump control
Stop mode

Feature / Function
Two stop modes are available as follows:
3AC
Normal stop
• Set p2370 = 0, All pumps running in line
operation are switched off simultaneously as
soon as the stop command is received.
• The pump in inverter operation stops under the
control of the inverter.
Sequence stop
• Set p2370 = 1, The pumps running in line
operation stop one by one in the reverse
Stop 1 Stop 2 Stop 3 Stop 4 sequence in which they are switched on. There is
a delay time (p29537) between every pump stop.
• The pump in inverter operation stops under the
control of the inverter after the other pumps are
switched off.
Confidential © Siemens AG 2018
Page 15
Multi-pump control
Service mode

Feature / Function
3AC

When a pump is in service mode, the inverter locks

the corresponding relay allowing to perform
troubleshooting of the pump without
interrupting the operation of other pumps.

Run 2 Run 3 Run 4

Confidential © Siemens AG 2018

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Multi-pump control
Cascade control

Feature/ Function
Consists of the speed-controlled main motor
and up to three other motors that are
switched-on or off via contactors or motor
starters, depending on:

• A fixed arrangement
• The operating hours

The PID deviation serves as the input signal

for activating the other motors. The contactors
or motor starters are switched by the drive's
digital outputs.

Usability: applications that require between 1 and

4 motors to be run at the same time depending on
load, so that e.g. highly variable pressure ratios or
flow volumes can be corrected

Confidential © Siemens AG 2018

Page 17
Pipe filling mode
Dismiss the hammer effect at the starting phase

Feature / Function

After each power-up, pipe filling mode allows the

inverter fills the pipe slowly to avoid hammer
effect to the pipe.

If the pipe filling is interrupted (for example, fault

occurs), the function continues after the inverter is
Output recovered

2 filling modes are available:

Operation
• Time mode
Pipe filling • Pressure mode

Time
Valve open

Confidential © Siemens AG 2018

Page 18
Deragging mode
Cleans blockage from impellers and protects the pump
Speed
Feature / Function
The deragging function is used to clean any
clogs/ obstructions on the pump impeller, pipes
or valves.
Time

This function consists on running the motor

forward and on reverse to clean the impeller.

Deragging mode can be enabled after power-up,

for every run or with an input signal.
(p29591).

Confidential © Siemens AG 2018

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Automatic restart increases availability

Automatic Restart (AR) Feature/ Function

Auto Auto Auto
No auto
No AR ack. ack. faults ack.
ack. faults
faults if ON/OFF =1 faults
Includes two functionalities after a fault that allow
No auto Auto Auto Auto to:
p1210 =0
switch on switch on switch on switch on
(default)
motor motor motor motor
• Automatically acknowledge all faults
After
After
power
After
After
power
• Automatically switch-on the motor again.
p1210= 1 power power p1210= 26
failure & failure &
failure failure
faults faults
Events recognized as power failure:
• Fault F30003 (undervoltage in the DC link), after
p1210=4 p1210=6 p1210=14 p1210=16
line voltage has been briefly interrupted.

• After all power supplies have been

interrupted and all the energy storage devices in
the inverter have discharged to such a level that
the inverter electronics fail.

Confidential © Siemens AG 2018

Page 20
Flying restart
Switching on while motor is running

Feature / Function

Auto flying restart pump

and fan After the ON command, the "flying restart" function
initially synchronizes the inverter output frequency
to the motor speed and then accelerates the motor
up to the set point.
Typical applications:
• Synchronization on a fan rotating even after
power failure
• The fan impeller is driven by the air flow
• Search current and search speed are adjustable.
• Searching also in the negative direction of
rotation (fan rotates in the reverse direction)

Confidential © Siemens AG 2018

Page 21
Skip frequency bands

Feature / Function

Speed bands exist in the set point channel to

prevent unwanted motor speeds.
The drive traverses through the set skip frequency
bands on the ramp function up / down generator,
but permanent operation in the set skip frequency
bands is not possible. This prevents an unwanted
speed from being permanently pending.
Advantages:
• Avoidance of resonance in the mechanical
system (e.g. pipelines / vent ducts)
• Reduced material fatigue
• Reduced noise pollution
• 4 skip frequency bands with mean speed and
bandwidth parameterizable

Confidential © Siemens AG 2018

Page 22
Real-time clock

Feature / Function
Real-time clock module Time
stamp

The real-time clock is a hardware clock in a chip,

which consists of a counter and a watch crystal as
the clock generator.
An energy accumulator is located in the device, so
that the clock does not stop when the device is
turned off.
It comprises the clock time in a 24 hour format
and the date in the "day, month, year" format.

Faults and alarms are provided with a time stamp It must be set once during commissioning. After
based on the real-time clock. This allows their clear a power supply interruption, the real time clock
relation with other activities in the production process, continues to run for approx. 5 days.
which may be related to the faults or have not them
caused at all.

Confidential © Siemens AG 2018

Page 23
Timer functionality

Feature / Function
Operating principle and functional diagram of a timer
switch

The timer function, along with the real time clock

in the inverter, offers the option of controlling when
signals are switched on and off.
Examples:
• Day/night switching of a temperature control
• Switching a process control from weekday to
weekend.

Confidential © Siemens AG 2018

Page 24
Keep running mode
To keep maximum availability

Overheat
Feature / Function
Reduce PWM frequency
Enables all possible functions to keep the
inverter away from faults and from tripping, by
applying configurable measures like:
Reduce speed
Overload • Reduction of the output speed and PWM
frequency to avoid over-temperature and
Reduce output current overload problems

Low-voltage • Catching running load and automatically

restarting the inverter after power disruption
Auto flying restart pump
(switches on drive while motor is running)
and fan

Power interruption • Using kinetic energy from the load to skip short
Kinetic buffering to skip time power interruption
interruption

Confidential © Siemens AG 2018

Page 25
PID controller

Feature / Function
Block diagram of a PID technology control The PID enables simple process control such
as line pressure, fill level, temperature, flow,
tension control or load balancing.
• The technology controller is implemented as a
PID controller (controller with proportional,
integral, and derivative action)
• Set point are specified via analog value, fixed set
points, motorized potentiometer, fieldbus
• The P, I and D components can be set
separately „
Example: Technology controller as a level controller
• The “I” component can be locked when the
control output is limited „
Control mechanism on a closed
loop feedback • Display and entry of set point and actual values
in technological dimensions

Confidential © Siemens AG 2018

Page 26
Dual ramp mode
Optimizes pump operation

Feature / Function

The dual ramp function allows the user to

Speed parameterize the inverter so that it can switch
from one ramp rate to another when ramping
up or down to a set point.

Quick Fast As a result, the inverter can be started

starting stopping smoothly and stopped quickly.
Time

No-return valve

Confidential © Siemens AG 2018

Page 27
Energy saving functionalities increase operation
performance and ensure reduced losses

Energy Saving Features

Economy mode

G120X Support of PMSM + RSM

Software
features Energy / flow calculator

Hibernation
Energy saving

Bypass Mode

Confidential © Siemens AG 2018 PMSM: Permanent Magnet Synchronous Motor

SRM: Synchronous Reluctance Motor
Page 28
ECO mode
Advanced energy saving/ motor control technology
Voltage Voltage
100% Feature / Function
80%

• Economy mode works by slightly changing the

Energy output voltage (via excitation current) either up
Without saving or down in order to find the minimum input power.
ECO
ECO

Speed Speed • Allows energy saving during low dynamic load,

such as pump and fan applications without
knowledge of the characteristic curve.

• If the load is changed, the control can adapt to

normal dynamic control to give the best
performance.

Confidential © Siemens AG 2018

Page 29
 Hibernation mode with PID
Smart features to save more energy
f
Feature / Function

Z Z
Sleep Z PID with hibernation allows to switch the pumps
to sleep mode when the drives are only being
Wake up deployed temporarily (by fixed set point or if the
offset is smaller than the setting) to avoid wasting
T energy by:

• Frequently starting and stopping the pump during

Energy low-load period causing increased pipe pressure
Operating Operating
Saving and energy waste.

• High pressure in the pipes that can cause

increased water loss even when the demand is
low.

Confidential © Siemens AG 2018

Page 30
Bypass mode switches the motor between inverter and line
operation

Feature / Function

When induction motors connected to a converter

are frequently operated in the rated motor speed
range, unnecessary losses are incurred.

In Bypass mode it is possible to "bypass" the

inverter electrically as soon as the motor
frequently operates close to its rated speed.

This helps to avoid inverter losses and increase

overall efficiency.

Confidential © Siemens AG 2018 Bypass function is only supported on induction motors up to <30 kW
Page 31
Energy/flow calculator
Estimate the running data without sensors

Feature / Function
3AC 1000111 00110001 • Without having a power meter or flow meter, the
G120X can estimate the energy saving from
Energy meter 110010 10000 the flow characteristic associated with a
01011000
mechanical flow control and the measured
electric power that is drawn.
• The calculation is suitable for centrifugal pumps,
fans, radial and axial compressors, for instance.
Flow meter
To set the characteristic, it is required from the
pump manufacturer:
• The flow characteristic associated with 5
selected speeds.
• At constant speed, the power drawn associated
with 5 flow rates, corresponds to the line
frequency and mechanical throttling of the flow
rate.

Confidential © Siemens AG 2018

Page 32
Protection features monitor current status in order to
increase safety of personnel and machinery

Protection Features
Blocking, leakage, dry-running
protection

G120X Rotation monitoring w. sensor

Software
features Condensation & Frost protection

Keep Running Mode

STO
Protection SIL 3

Fire mode

Cavitation protection

Confidential © Siemens AG 2018

Page 33
Condensation and frost protection
“avoids damage to the motor and pump”

Feature / Function

Condensation protection:
Motors in a humid and cold environment can
develop condensation which could cause motor
failure.
This problem can be avoided by slightly
increasing the temperature of motor surface by
(humid air → condensed water)
applying a DC current to keep the motor warm to
prevent condensation.

Frost protection:
The water frozen inside of a pump can cause
damage. The slow movement of the impeller
while it’s not being operated or when the
surrounding temperature falls below a threshold
can prevent damage.

Confidential © Siemens AG 2018

Page 34
Cavitation protection
“Keeps cavitation damage away”

Feature / Function

The impeller from the pump can be damaged by

little bubbles which are generated by the pressure
gap when the pump is running at high speed and
Available head of water

the water can not be supplied as required.

Required head of water

The cavitation protection generates a warning

when cavitation pressure thresholds are
reached. If the inverter gets no feedback from the
pump transducer, it will trip to prevent cavitation
damage.

Warning

Stop

Cavitation is the formation of vapor cavities in a liquid,

Confidential © Siemens AG 2018
small liquid-free zones ("bubbles" or "voids")
Page 35
Pump blockage, leakage & dry running protection
Protects the pump from abnormal load situations

Feature / Function
Torque

Warning The inverter can keep track of the speed,

Blocked
current and the torque of the motor to
determine abnormal load situations:
Leakage Stop

• Insufficient torque can indicate leakage or dry-

Dry run Speed running

• Excessive torque (and current) together with

low speed can indicate machine blockage

• Insufficient motor current indicates that the

power transmission from the motor to the load is
interrupted (no load)

Confidential © Siemens AG 2018

Page 36
Essential Service Mode “inverter attempts to operate the motor for
as long as possible despite irregular ambient conditions”.

Feature / Function

During Fire mode, the inverter attempts to

operate the motor for as long as possible
ON (ignoring the OFF signal) despite irregular
set point
ambient conditions to improve the air circulation
and survival time on critical situations
Keep fans working to give the
pressure in the stair well to
force the fireproof door close to
reduce the spread of fire and
smoke

Fire
door
The pump system also can use
ESM to keep fire-fighting
system running

Confidential © Siemens AG 2018

Page 37
Agenda

1 Product introduction

2 System Overview

3 Pump and Fan control Functions

5 Selection and Commissioning

4 Technical Details

Confidential © Siemens AG 2018

Page 38
G120X is implemented in SIZER V3.19

Confidential © Siemens AG 2018

Page 39
Smart Access Module
Webserver via Wi-Fi

Smart Access Module (SAM) Mobile Device View

(Additional WLAN Access Point required)
Faster commissioning with improved setup

• A faster commissioning mode is presented for the G120X to

fulfill branch application setup (Pump, Fan, Heavy-duty)
• In parallel, the classic quick commission is kept for the rest of
the G120 family

Up to 50m

SAM: Smart-Access-Module
Confidential © Siemens AG 2018
Page 40
Smart Access Module
Presents a new quick commissioning mode

Application Motor I/O Important Motor Config. Is

selection data configuration (key) parameters ID Finished

Prefilled standard Preselected standard Prefilled

macro

The new G120X SAM’ commissioning mode enables a faster P&F setup solution

Confidential © Siemens AG 2018

Page 41
G120X seamlessly blends into
GMC Digitalization

TIA Portal (GSD), TIA Portal (GSD), TIA Portal (GSD), IOP-2,
SINAMICS Web SINAMICS Web SINAMICS Web server,
server, IOP-2 server, IOP-2 Analyze MyDrives

APP:
in-cloud

Analyze My
Drives Product Production Production Production Services
design planning engineering execution

Machine Machine Machine Machine Machine

data concept engineering commissioning operation services
in-line

SINAMICS connect
NX MCD, SIZER, E- DT Configurator, SIZE, SAM (webserver), SAM (webserver), IOP-2, SAM
in-machine

Plan IOP-2 IOP-2 (webserver), Analyze

2 wire

2 wire

2 wire
PTP

PTP

PTP

MyDrives

RS2321
G120X can… • ... simply be connected to the cloud
Up to 8
drives • ... visualize important operating states
G120X • ... show the need for service → AMD
1 RS232: SUB-D 9pol
Confidential © Siemens AG 2018
Page 48
Agenda

1 Product introduction

2 System Overview

3 Pump and Fan control Functions

5 Selection and Commissioning

4 Technical Details

Confidential © Siemens AG 2018

Page 49
SINAIMICS G120X/XA
General information
G120X G120XA
Power range: Power range:
• 3AC230V 0.75 ~ 250kW

• 3AC400V 0.75 ~ 560kW • 3AC400V 0.75 ~ 560kW
• 3AC690V 3 ~ 630kW

Rich I/O • Rich I/O

• Digital inputs x 6 + Extension • Digital inputs x 6
• Analog inputs x 2 + Extension  • Analog inputs x 2
• Relay outputs x 2 + Extension • Relay outputs x 4 (230V AC)
• Analog output x 1 + Extension • Analog outputs x 2

I/O Extension Module

• 2DI, 2AO, 4DO (relay), 2x Pt1000 or • -
Ni1000
Integrated communication
Integrated communication
• USS
• PROFINET 
• MODBUS RTU
• EtherNet IP
• BACnet MS/TP

Certification Certification

CE, cUL, UL, KC, RCM, EAC RoHSII, CE, RCM, EAC
Confidential © Siemens AG 2018
Page 50
SINAMICS G120X/XA offers comprehensive functionality
and creates added value
G120X G120XA
Dedicated user interface with optimized Dedicated user interface with optimized

SAM (webserver) and IOP-2 SAM (webserver) and IOP-2

Optimized design: 3C3 coating1

Optimized design: 3C2 coating +
(optional)+ extended operating
 extended operating temperatures
temperatures
-20˚C to 40 …60˚C (with derating)3
-20˚C to 45 …60˚C (with derating)3

EMC compliant (C1 + C2) and EMC compliant (C3) and


Integrated DC-link choke integrated DC-link choke

Safe Torque Off SIL 3 hardware  -

Compatible with SINAMICS connect Compatible with SINAMICS connect

and TIA Portal via GSD file


Pluggable I/O terminal hardware and

optional repair switch (for IP55/UL122)
 Pluggable I/O terminal

LO rating: 110%/60s/300s
 Overload:110%/60s/300s
HO rating: 150%/60s/300s

IOP-2: Intelligent Operator Panel 1 in preparation

Confidential © Siemens AG 2018 2 Available
SAM: Smart Access Module on 12/2019
Page 51
SINAMICS G120X top 5 highlights include seamless,
cost efficient, robust, time saving and digitalization features

Seamless, • Wide power and voltage range = 0.75 kW … 630 kW/1 ... 700 HP SINAMICS G120X
simple, • One MLFB = Fast and simple to order, runner types on stock
time saving • Out of the box = Easy handling

• DC-link choke = No external input chokes

Cost efficient • Long cable lengths = Reduced need for output chokes
• Energy efficiency solutions in focus (G120X+RSM)

• 3C3 coating1 = Operation under harsh environments

Robust
• Integrated DC- Link choke enhances grid/device protection
and reliable
• Safety functions = STO SIL3 functionality
FSC, IP55
UL type 12
• Service switch = Simple grid disconnection in IP55
Dedicated
• DT-Configurator/SSAPP = Improved selection, incl. bidding text
to segments
• Firmware = dedicated features e.g. Deragging, Multi Pump Control

• SINAMICS connect for cloud based analytics

Fit for • Smart Access Module comfortable setup and diagnostics
digitalization • Communication via PROFINET, PROFIBUS, Modbus RTU,
BACnet G120X FSA .. J, IP20
RSM Reluctance Synchronous Motor | SSAP SINAMICS Selector APP UL open type
1 in preparation RSM: Reluctance Synchronous Motor
Confidential © Siemens AG 2018
SSAP: SINAMICS Selector APP
Page 52
SINAMCIS G120XA make the pump and fan smarter

[Link]

Confidential © Siemens AG 2018

Page 53