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Mastering the SINAMICS G120 – Modular Drive Configuration Explained
The SINAMICS G120 is one of Siemens' most versatile and widely used variable frequency drives (VFDs). But if you’re new to its modular architecture, it can feel like a puzzle—PM modules, CU modules, BOP interfaces… which ones do you need? In this guide, we’ll break down each component and show how to confidently build or replace your SINAMICS G120 system for everything from conveyors to compressors.
What Makes the G120 Different?
Unlike all-in-one drives, the G120 is modular by design. That means you select and connect its core components separately, giving you flexibility for:
- Power scaling
- Communication options
- Application-specific interfaces
- Easier maintenance and upgrades
Example: A G120 used in a fan application might use a PM240-2 Power Module (7.5 kW), a CU240E-2 PN for Ethernet control, and an IOP for local diagnostics.
1. Choosing the Right Power Module (PM)
Power Modules supply energy to the motor and determine the drive’s power rating. Options include:
- PM240-2: Standard module, supports regenerative braking with external resistor
- PM250: Built-in braking chopper for dynamic loads (e.g., hoists, lifts)
- PM260: Advanced version for regenerative feedback
| Power Range | Voltage Range | Common Use |
|---|---|---|
| 0.55 kW – 250 kW | 200–690V (varies) | Pumps, fans, conveyors |
| PM240-2 Module Example | 6SL3210-1PE23-5UL0 | 3.5 kW, 480V, IP20, book size |
From the Manual: Each PM module has specific cooling requirements (e.g., IP20 open frame vs. IP55 enclosed)—vital for panel layout planning.
2. Selecting a Control Unit (CU)
The CU handles signal processing, I/O, and communication protocols.
Popular CU models:
- CU240E-2 B: Basic, with analog/digital I/O
- CU240E-2 PN: Includes PROFINET and safety features
- CU250S-2: Advanced vector control, encoder feedback, and expanded I/O
| CU Model | Features | Best For |
|---|---|---|
| CU240E-2 B | Standard I/O, analog control | General-purpose machines |
| CU240E-2 PN | PROFINET comm, safety relays | Networked motion applications |
| CU250S-2 | Encoder input, closed-loop vector | Positioning and tension control |
Tech Tip: Each CU must match the firmware compatibility of the PM. Siemens recommends always updating the firmware via STARTER or TIA Portal.
3. Operator Interfaces: BOP vs. IOP
Need local diagnostics or easy commissioning? You’ll need a Human-Machine Interface (HMI).
- BOP-2 (Basic Operator Panel): Simple screen with basic parameter access
- IOP (Intelligent Operator Panel): Full text display, wizards, trend views
- IOP-2: Faster, better diagnostics, and USB interface
| Panel | Best Use |
|---|---|
| BOP-2 | Minimal interaction environments |
| IOP | Setup and regular diagnostics |
| IOP-2 | Complex drives with frequent tuning |
From the Manual: The IOP-2 allows up to 100 parameter sets to be stored and transferred—ideal for OEMs configuring multiple machines.
4. Optional Accessories to Consider
- Braking Resistors: Necessary with PM240-2 when using dynamic loads
- Line Filters (e.g., SINAMICS LC filters): Reduce harmonics for compliance
- Profibus/PROFINET Modules: Enable flexible industrial network integration
- Safety Modules: Integrated STO (Safe Torque Off) in most CU options
Sample Configuration – Conveyor System (10 HP)
Let’s say you’re building a 10 HP conveyor drive:
- Power Module: 6SL3210-1PE23-5UL0 (PM240-2, 7.5 kW, 400V)
- Control Unit: CU240E-2 PN (with PROFINET)
- Operator Panel: IOP-2 for local control
- Braking Resistor: External 820-ohm resistor for deceleration
Tip: Always check your load type and deceleration profile before selecting braking components.
Why Technicians Love the G120
- Easy to swap individual components without replacing the full drive
- Pre-tested application macros simplify commissioning
- Integration with TIA Portal and STARTER software for fast diagnostics
- Modular spares reduce cost of repairs
In-Stock SINAMICS G120 Modules at Industrial Automation Co.
We carry a full range of SINAMICS G120 parts and replacements:
- 6SL3210-1PE23-5UL0 – PM240-2 Power Module, 7.5 kW
- 6SL3244-0BB13-1FA1 – CU240E-2 PN Control Unit
- 6SL3255-0AA00-4HA1 – Braking resistor, 820Ω
- 6SL3255-0AA00-4JA1 – IOP Intelligent Operator Panel
- 6SL3255-0AA00-4CA1 – BOP-2 Basic Panel
Need Help Building the Right G120 System?
Whether you're modernizing a drive panel or replacing a failed module, our team can help you identify compatible SINAMICS G120 components fast. We offer same-day shipping and expert recommendations for a wide range of Siemens applications.