G120E_app_notes_ext_r1_2.

doc Page 1 of 3 April 2013

SINAMICS G120E Fasttrack enclosed drive Application notes
SINAMICS G120E Fasttrack is an enclosed drive based on SINAMICS G120 components, rated 1 to 200 HP at
460 V, with a limited range of predesigned power circuit and control options to achieve the best lead times.
1.0
The SINAMICS G120E base unit includes as standard:
Base unit & options
NEMA 1 enclosure, with blowers
UL listing per UL508C, file # E319311
SCCR (short circuit current rating) of 65 kA
Circuit breaker disconnect with through the door operator
Power module PM240 (non-regenerative) or PM250 (fully regenerative), unfiltered
Input line reactor (approx. 2.5%) for PM240 (line reactor is not required for PM250)
A control unit from the list of available units (mandatory option)
Intelligent operator panel (IOP), door mounted
CPT for internal 115V, 1 ph AC and if needed a DC supply (e.g. for communication bus converters)
1.1
Available power options are:
Power options
Input fuses
Input contactor
Input line reactor 5% nominal impedance (for PM240 only)
Output reactor
2 contactor bypass (output & bypass contactors, mechanically interlocked, with motor O/L relay), with control
switch VFD-OFF-BYPASS and indicator lights BYPASS READY and BYPASS ON.
1.2
Available control options are:
Control options
Control unit (mandatory option): Choose one of CU230P-2 HVAC, CU230P-2 DP, CU230P-2 PN, CU240E-2,
CU240E-2 DP, CU240E-2 PN, CU240E-2 F, CU240E-2 DP-F, CU240E-2 PN-F, CU250S-2, CU250S-2 DP,
CU250S-2 PN
Bus communication protocols are determined by the control unit:
o EtherNet/IP and PROFINET on CU230P-2 PN, CU240E-2 PN, CU240E-2 PN-F, CU250S-2 PN
o PROFIBUS on CU230P-2 DP, CU240E-2 DP, CU240E-2 DP-F, CU250S-2 DP
o Modbus RTU and USS on CU230P-2 HVAC, CU240E-2, CU240E-2 F, CU250S-2,
o BACnet MS/TP on CU230P-2 HVAC
Expanded voltage range 380 480 V (standard is 460 480 V)
2.0
SINAMICS G120E is an enclosed drive listed to UL508C (Power Conversion Equipment) per UL file # E319311,
by part number. (This is the same listing used for example for SINAMICS power modules). Listing per UL508C
means that the drive is a predesigned standard product that has been evaluated/ tested by UL.
Modifications by 3
rd
parties
This implies that the product as manufactured by the factory may not be modified by third parties, not
even by a panel shop listed to UL508A.
Any unauthorized modifications will invalidate the UL listing (and warranty) of the SINAMICS G120E drive.
Please consult the factory If there are any questions.
3.0
Some output current ratings of SINAMICS G120 enclosed drives are lower than the corresponding power module
ratings published in catalog D31 SINAMICS and Motors for Single-Axis Drives. This is to compensate for the
temperature rise inside the drive enclosure (the components inside the enclosure operate at approx. 45C/113F
at an external ambient temperature of 40C/104F).
Ratings
This needs to be considered when operating/derating the drive for operation at ambient temperatures above
40C/104F using the derating curves in catalog D31 or the hardware manuals.



G120E_app_notes_ext_r1_2.doc Page 2 of 3 April 2013
4.0
The standard SINAMICS G120 enclosure is oversized to accommodate all standard options, and there is also
space for additional components/devices installed by others.
Enclosure
4.1
Both top and bottom cable entry for line, motor and control cables is provided.
Cable entry
4.2
Line side cables are always terminated on the line side terminals of the circuit breaker. A ground terminal is
provided as well.
Cable terminations power and control wiring
In the base unit, motor cables are terminated on the power module output terminals. Separate motor terminals
are provided with output options, as appropriate.
Customer control wiring connection is directly to the control unit terminals.
For input or output contactor options, the contactor control circuits (115 V AC, 1 ph.) is wired to terminals for
connection of control actuators/devices or PLC I/O provided by others. For an input contactor these terminals
are bridged in the factory, so the contactor closes as soon as input power is applied. The drive controller will
open the contactor under certain conditions, for example in the event of a fault.
A 2-contactor bypass includes a VFD-OFF-BYPASS selector switch BYPASS READY and BYPASS RUN pilot
lights. With factory default wiring, switching the selector switch to BYPASS will close the bypass contactor (and
open the output and if present input contactors). Terminals for connecting other pilot devices are provided.
5.0
Each SINAMICS G120 enclosed drive will be supplied with the following documentation:
Documentation
One paper set of schematic and outline dimension drawings for the particular configuration ordered, and a test
certificate. Drawings are standard drawings, and do not include order or customer specific text.
A CD with:
o the SINAMICS G120 catalog (D31), SINAMICS G120 hardware and firmware manuals in pdf format
o Configurator (Excel) for list of drawings and spare parts list.
o a full set of standard schematic and outline dimension drawings (for all ratings and all configurations of
standard options) in pdf format.
The drive nameplate will list the drawings applicable to the particular configuration.
Note: AutoCad (.dwg or .dxf) format is available from the factory, on request. This enables AutoCad users to
modify the standard base unit drawings, and add project and customer information when required.




G120E_app_notes_ext_r1_2.doc Page 3 of 3 April 2013
6.0
6.1 Why is a control unit a mandatory option? Why not simply offer the base unit without a CU?
FAQs
Some CUs (CU2xx-2) can connect directly to the IOP, others require a PC connection kit and
external DC power supply, plus appropriate wiring.
By making the CU a mandatory option, we ensure that all required components and wiring are
included. This allows us to ship a fully tested and functioning enclosed drive unit.
6.2 Can a UL listed panel shop add a bypass circuit to the G120E provided the design and
mounting/wiring are done in accordance with UL508A requirements?
NO, not inside the drive enclosure.
A SINAMICS G120E enclosed drive is not an industrial control panel listed per UL508A, but a power
conversion unit listed per UL508C. Only the original manufacturer can provide power circuit options
that are included in the UL508C listing for the drive.
(In a UL508C listed product, items such as short circuit protection and conductor cross sections are
not necessarily with UL508A requirements. However, it is proven by test that the drives performance
meet UL requirements including the short circuit current rating. Any deviations to the specific design
are not evaluated by UL, and will invalidate the UL508C listing).
It is however possible for a 3
rd
party to add an external bypass in a separate UL508A industrial control
panel. This external circuit must be connected to the input and output terminals of the SINAMICS
G120E. It is not possible to use the drive input circuit breaker disconnect as a protective device for
the external bypass circuit.
6.3 The nameplate of my SINAMICS G120E shows an SCCR of 65 kA. However, per the UL508C file of
the power modules >20 HP they need to be protected by the listed fuses to achieve a high SCCR
of 65 kA. Did the factory forget to install the fuses?
No, the factory did not forget the fueses.
SINAMICS G120E is an enclosed power converter listed per UL508C, similar to the power modules
themselves. The complete range of enclosed units was evaluated by UL including short circuit
testing, and UL confirmed that the design of the G120E is suitable for connection to a power supply
with a short circuit rating of up to 65 kA, without fuses.
However, for an industrial control panel designed and built per UL508A the SCCR is determined per
UL508A supplement SB, and the UL listing of the individual components is applicable. The standard
SCCR of SINAMICS G120 power modules is 5 kA (25 to 50 HP) respectively 10 kA (60 to 200 HP).
To achieve a high SCCR rating of up to 65 kA it is necessary to install the fuses required per the
UL508C file of the power modules.
6.4 SINAMICS G120E is supplied with UL listing in a NEMA 1 enclosure, without air filters. However
for SINAMICS G150 the documentation states that air filters are required for UL listing. Is this a
mistake?
No mistake.
SINAMICS G120E is listed as a power converter per UL508C, and per its UL listing its NEMA 1/UL
type 1 enclosure does not require to be fitted with air filters.
In contrast, SINAMICS G150 is listed under UL508A (enclosed industrial control panel). Per UL508A
section 26.5 air filters are required. UL508A states:
26.5 Air filters
26.5.1 Air filters shall be provided over ventilation openings in enclosures containing power
conversion equipment, programmable controllers, power supplies, and information technology
equipment.
Exception: An air filter is not required over ventilation openings when fans are not provided in the
enclosure or an integral part of any component in the enclosure.
26.5.1 effective April 25, 2003