Siemens VFD Drives: SINAMICS Series Overview, Alternatives & Repair Solutions

Siemens SINAMICS VFD Family Overview

The Siemens SINAMICS series is designed to cover virtually every motor control need, from basic single-motor control to complex multi-axis systems. Siemens' portfolio spans low-voltage drives for common factory voltages (230 V, 480 V, 600 V) as well as medium-voltage drives for higher power requirements. The SINAMICS range covers power ratings from as low as 0.12 kW up to 85 MW, encompassing everything from small fans to gigantic mill drives. This breadth means Siemens likely has a drive for every conceivable application.

The product family is divided into series targeting different segments:

• SINAMICS V-Series: Entry-level, compact drives for simple applications. The SINAMICS V20 is a low-cost VFD for basic motion sequences, emphasizing quick setup and cost efficiency. It handles small motors in pumps, fans, conveyors, and more, with models from 0.12 kW up to 30 kW (approx. 1/6 HP to 40 HP). It features an integrated operator panel and energy-saving functions like automatic flux optimization. Its robustness and wide voltage range (single-phase 230 V or three-phase 400–480 V) make it a popular choice for OEM machinery needing an affordable drive solution.
• SINAMICS G-Series: General-purpose AC drives for industrial motors, typically featuring more performance and options than the V-series. A key model is the SINAMICS G120, a modular drive system with a separate power module and control unit, allowing flexibility in power rating and control features. G120 drives cover a wide power range from around 0.55 kW up to 250 kW (approx. 0.75 to 335 HP). Variants include the G120C (Compact) for an all-in-one design up to ~150 HP, and the G120X tailored for pump, fan, and compressor applications with specialized PID controls and simplified HVAC programming. For high-power needs at low voltage, Siemens offers chassis and cabinet drives like SINAMICS G130/G150, which extend into the hundreds of kW for heavy-duty conveyors, extruders, or large pumps. These G-series drives generally support advanced motor control modes (sensorless vector, V/Hz, and optional encoder feedback for closed-loop control), and many include built-in safety features (like Safe Torque Off) and EMI/RFI filters to meet EMC standards. The Sinamics G series is a fully integrated solution in the TIA (Totally Integrated Automation) framework, communicating easily with Siemens PLCs (SIMATIC) and HMI systems.
• SINAMICS S-Series: Built for high-performance motion control and servo applications. The flagship is the SINAMICS S120, a modular multi-axis drive system used for coordinated drive systems like packaging machines, printing presses, and robotics. S120 drives support regenerative feedback, fast response, and can drive both induction and permanent-magnet servo motors. The S-series typically includes advanced positioning, synchronization, and safety functions. These drives may replace older Siemens MasterDrive or SIMODRIVE systems. Power ranges for S120 can be broad, from a few kW per axis up to hundreds of kW in a multi-drive lineup. Siemens also offers specialized servo drives like the SINAMICS V90 (a compact servo drive system often paired with Siemens SIMOTICS S-1FL6 servo motors).

Medium Voltage & DC Drives

While the focus is on low-voltage AC drives (typically ≤690 V AC input), Siemens also covers medium-voltage drives under the SINAMICS brand. Models like SINAMICS GM150/GL150 and SINAMICS GH180 cater to medium-voltage applications, running large motors in pipelines, mining, and metals. These can reach enormous power levels. Siemens also produces DC drives (thyristor-based converters for DC motors) under the SINAMICS DC Master series.

Legacy Note: Predecessors to SINAMICS

Siemens' current drive lineup (SINAMICS) was preceded by the MICROMASTER series and SIMOVERT/MASTERDRIVES in past decades. Many industries still have Micromaster 420/440 VFDs or MasterDrive units in operation. Siemens began phasing out the Micromaster family in favor of SINAMICS over the last 10+ years, with the Micromaster 4 series having reached its limits of functionality and performance. Final Micromaster production is winding down, with official product cancellation for some models scheduled by 2027. The newer SINAMICS drives offer advantages over the old Micromasters, including higher power capacity, integrated PROFINET/EtherNet/IP communications, built-in safety functions, better efficiency, and modern configuration tools. Siemens and distributors like RS Components provide retrofit kits and selection guides to help users replace Micromaster units with the appropriate SINAMICS equivalent. For example, a Micromaster 440 used on a pump could be replaced by a SINAMICS G120 or G120X drive, usually with minor wiring and parameter changes. It is wise to plan for this generation change, and Precision Electric can assist by identifying drop-in replacements or retrofit solutions.

Performance and Features of Siemens VFDs

Siemens SINAMICS drives are known for their engineering and robust features, aligning with industry standards and advanced requirements:

• Motor Control Modes: SINAMICS drives support simple V/f (volts-per-hertz) control for basic applications and vector control for higher performance. Many models offer both open-loop vector (no encoder required) and closed-loop vector (with encoder feedback) for precise speed or torque regulation. This is comparable to other top brands.
• Overload Capability: Siemens specifies different duty classes (e.g., low overload vs high overload) for their drives. A SINAMICS drive might be rated for 110% of nominal current for 60 seconds (normal duty) or 150% for 60 seconds (heavy duty). This flexible overload rating allows for using a smaller drive if the application only occasionally needs high torque. The SINAMICS G120, for example, has parameterizable load duty profiles.
• Energy Efficiency: SINAMICS drives improve energy efficiency by varying motor speed to match demand, offering significant energy savings on variable torque loads (fans, pumps). Siemens integrates features to maximize drive efficiency, such as the V20's automatic flux reduction and ECO mode. SINAMICS drives can display energy consumption and savings in real time. They can also go into standby or “hibernation” when not needed. These energy-focused functions help companies meet efficiency goals and sustainability targets.
• Built-in Protections and Standards: Siemens designs its drives to meet global standards like IEC 61800-5-1 (safety requirements for adjustable speed drives) and IEC 61800-3 (EMC requirements). SINAMICS drives include protective features such as overload protection, overvoltage/undervoltage ride-through, and often EMI filters to curb electrical noise. Many SINAMICS units have internal EMC filters to meet CE (EN 61800-3) emission categories. The drives are also UL listed for use in the US, typically. Siemens offers various enclosure ratings – IP20/open style for panel mounting, IP55/NEMA12 or higher for direct machine mounting. Temperature and altitude ratings are in line with industry norms, and conformal coating options for circuit boards are available for harsh environments.
• Communication and Integration: SINAMICS drives naturally support PROFINET and PROFIBUS networks. Many models also support Modbus RTU or Modbus TCP, and newer ones can do EtherNet/IP. Siemens offers optional communication modules or versions of G120 that speak EtherNet/IP to make multi-vendor integration easier. Drives from all major vendors aim to be compatible in heterogeneous systems. Siemens drives also come with PC tools (like StartDrive integrated in TIA Portal, or SINAMICS Starter software) for configuration, and even a mobile app interface. The SINAMICS V20 has an optional "Smart Access Module” which creates a Wi-Fi hotspot on the drive, allowing configuration and monitoring from a phone or laptop browser wirelessly.
• Safety and Functional Features: Many SINAMICS drives have Safety Integrated functions. For instance, Safe Torque Off (STO) is often on-board and SIL 2 or SIL 3 rated, meaning the drive can form part of a safety system to quickly remove torque without external contactors. Higher-end models can also provide safe stopping ramps (SS1), safe limited speed (SLS), etc. These features are crucial in applications like machine tools or presses. Siemens drives incorporate programmable I/O and logic that can handle simpler control tasks internally. The drives often include PID controllers for process control and multi-motor control for pump alternation. For example, the SINAMICS V20 has macros for different control schemes and can clone parameters between drives easily via an SD card or the optional keypad loader.

Alternatives to Siemens VFDs from Other Manufacturers

While Siemens is among the top VFD makers globally, there are numerous alternatives that offer comparable performance and features. Depending on your application and support needs, you might consider drives from ABB, Rockwell (Allen-Bradley), Schneider Electric, Mitsubishi, Danfoss, Yaskawa, Hitachi, Eaton, WEG, Lenze, Toshiba, and others. Each of these companies has a range of drive series that align with similar niches as Siemens' SINAMICS line. The major VFD manufacturers often leapfrog each other in technology.

• ABB Drives: ABB is one of the largest drive manufacturers, known for quality and innovation. Their current low-voltage drive lineup includes the ACS series drives. For general purpose use, ABB offers the ACS580 and ACS480 (for basic to standard drives) and the higher-performance ACS880 series for industrial applications. The ABB ACS880 is a flagship drive family that covers power ratings up to 6000 kW (over 8000 HP) in low-voltage configurations. ACS880 drives use ABB's proprietary Direct Torque Control (DTC) algorithm, which gives extremely precise torque control without encoders and very fast response. An ACS880 or ACS580 can often replace a comparable Siemens drive with minimal differences in performance. ABB also offers specialized variants (ACS310 for pumps/fans, ACS800 series for multi-drive systems, etc.). ABB drives have a widespread support network and documentation.
• Yaskawa: Yaskawa Electric is another top VFD producer, praised for rock-solid reliability. Yaskawa drives are known to run for decades with minimal issues, and their documentation and support are considered among the best in the industry. Yaskawa's current lineup includes the GA500 and GA800 series for general purpose use. The Yaskawa GA800 is a heavy-duty drive series that spans 0.75 HP up to 1000 HP. It's a direct competitor to Siemens SINAMICS G120/G130 or ABB ACS880. GA800 drives feature advanced vector control, permanent magnet motor support, built-in EMC filters and integrated functional safety (STO) up to SIL3. For smaller motors, the Yaskawa GA500 covers fractional to ~30 HP sizes and is very compact, with programming macros for fans, conveyors, etc. Yaskawa is known for ease of use, with straightforward parameter menu structures and tools like DriveWizard Mobile. Yaskawa maintains backward compatibility in control interfaces, easing the learning curve. Yaskawa drives are widely stocked in the US, reasonably priced, and can be configured to mimic the accel/decel and control logic of the old drive in most cases.
• Hitachi: Hitachi Industrial Equipment produces a range of drives that can substitute in many scenarios. A notable example is the Hitachi SJ-P1 series, which is a high-performance drive up to about 450 HP. Hitachi drives like the SJ-P1 come with both sensorless and closed-loop vector modes, and include built-in logic programming and even some IoT integration features. For mid-range needs, Hitachi's older WJ200 series (0.5–20 HP range) was popular in packaging and HVAC; it has since been succeeded by newer models (NES1 and WJ500 series, etc.). If you have a smaller Siemens drive (say a SINAMICS V20 on a machine) and need an alternative, a Hitachi WJ200 or its successor could fill the role.
• Danfoss & Eaton: Danfoss and Eaton deserve mention together because many of Eaton's VFDs are actually made by Danfoss. For instance, the Eaton SVX9000 and SPX9000 drive series were OEM'd from Danfoss's VLT line. If an Eaton drive is obsolete or not in stock, you could use the equivalent Danfoss model and it will plug right in, with the same physical dimensions and nearly identical parameters. Danfoss drives are high-quality, especially for HVAC and refrigeration applications. Eaton's current PowerXL series (like DG1 general-purpose drives, and DP1, DH1, etc.) are also very capable. Eaton touts features like an Active Energy Control algorithm that can automatically trim motor voltage to save extra energy at light loads, boasting up to 10% additional energy savings beyond standard VFD operation. This is comparable to Siemens drives running in optimized flux mode.
• Lenze (AC Tech): Lenze produces a variety of compact drives often found in packaging, food/beverage, and OEM equipment. The Lenze i500 series is a modern, modular inverter family that covers roughly 0.33 HP up to 175 HP in a very space-saving form factor. Lenze drives are known for their compact design. In the North American market, many know Lenze through the AC Tech SMVector drives (NEMA 4X washdown drives commonly used for conveyors, mixers, etc.). Those older models (SMV, SCF series) were discontinued by 2019 in favor of the new Lenze i-series. Lenze drives are typically straightforward to set up for basic speed control, and the newer ones offer advanced capabilities.
• Schneider Electric (Square D): Schneider's Altivar line of VFDs (e.g., Altivar 320, 610, 960 etc.) competes in the same market. If you have a preference for Schneider/Square D, their drives are quite capable. For example, an Altivar 630 is a pump/fan drive similar in concept to a Siemens G120X, and an Altivar 980 would be a high-performance drive akin to a Siemens S120. Other reputable brands include Mitsubishi FREQROL, Fuji Frenic, WEG CFW series, Toshiba VF-series, etc. In most cases, any major-brand VFD can be configured to work in a given application as long as the voltage, current, and basic control features match.

Key Considerations When Switching Brands

If you plan to replace a Siemens VFD with another brand, there are a few things to keep in mind for a smooth transition:

• Physical size and mounting: The dimensions and weight of the new drive might differ. You may need to adjust panel layouts or drill new mounting holes. Check heat dissipation and clearance requirements. Some brands provide adapter plates to match competitor mounting hole patterns.
• Motor compatibility: Ensure the new drive can handle your motor's requirements, including voltage and full load amperage (plus overload), and whether the motor is standard induction or something special (e.g., a high-speed spindle or a permanent magnet motor).
• Control wiring and I/O: Map out the control terminals from the Siemens drive (start/stop commands, analog input for speed, etc.) and identify equivalent terminals on the new drive. Careful cross-referencing is needed. Verify if any special functions were used.
• Parameter programming: Before removing the old drive, back up the parameters or record key settings (motor nameplate data, accel/decel time, min/max frequency, custom V/F profile tweaks, multi-speed presets, etc.). Then program the new drive accordingly. Precision Electric's technicians routinely program new drives to match the old logic. They can even pre-program a replacement drive before shipment if you provide the parameters or a description of the required settings.
• Standards and approvals: Ensure the new drive meets your facility's specific standards (like UL508A panel compliance, or IEEE-519 harmonic limits for line harmonics). IEEE-519 compliance might require adding input reactors or using a drive with low-harmonic technology. If the Siemens drive was UL-listed and your panel requires UL components, make sure the new drive is UL listed or recognized as well.

Repair and Support for Siemens and Other VFDs

Precision Electric diagnoses VFDs on a full-load test bench. Precision Electric, Inc. supplies new drives and is also a factory-level repair center for VFDs, servo drives, motors, and related industrial electronics. Their goal is to help customers minimize downtime, whether by promptly repairing a failed drive or providing a quick replacement. For Siemens VFDs, they offer both services: they can repair many models of Siemens drives (from legacy Micromaster units to newer Sinamics series), and they can propose alternatives if a Siemens unit is obsolete or backordered.

• In-House VFD Repair: Precision Electric performs 99% of drive repairs in-house, controlling turnaround time and quality. Repaired drives are fully tested under load before return. They stock common failure components and use diagnostic tools and manufacturer manuals to troubleshoot down to the component level. All repairs include a 12-month in-service warranty.
• Downtime Mitigation: A failed VFD can bring production to a standstill, costing thousands per hour. Emergency repair service is available, with drive repairs completed in as fast as 2-3 days (depending on parts availability). They emphasize speed, aiming to get customers back up in days instead of weeks. They also keep an inventory of loaner drives and can facilitate overnight shipment of a replacement.
• On-Site Support: Precision Electric's repair model is primarily ship-in service. They offer on-site field service for certain regions and scenarios (especially for larger systems or integration projects), but do not generally dispatch emergency field technicians nationwide to troubleshoot drives on-site. Many customers mitigate downtime by keeping a spare drive or contacting Precision Electric for a rapid replacement unit, then sending the damaged drive for repair.

Real-World Examples of How Precision Electric Helped Customers Avoid Downtime

• ABB Pulp Mill Upgrade: An aging pulp mill upgraded to new ABB ACS580 drives during a planned shutdown, keeping removed ACS550 units as spares. This cut unplanned drive failures by 76% and provided spare hardware.
• Yaskawa Spare Saves the Day: A beverage production facility purchased a spare Yaskawa GA500 drive during a chip shortage. When a critical mixer drive failed, they installed the GA500 spare, averting any production loss. The failed drive was sent for repair and later shelved as a backup.
• Hitachi Obsolete Drive Refurbishment: A packaging line relied on a 15 kW Hitachi WJ200 drive. When it began tripping erratically, the team found out that model was recently obsoleted and the new replacement was backordered. Precision Electric repaired the WJ200, replacing a failing output transistor module and dried DC bus capacitors, returning it in four days. The line resumed operation without needing any electrical modifications.
• Lenze 8200 GFCI Issue: A plastics manufacturer had a legacy Lenze 8200 Vector VFD tripping the ground-fault interrupter (GFI) breaker. Precision Electric serviced the drive by altering the EMI filter configuration and adding ferrite chokes on the output to reduce high-frequency leakage. They also helped the customer source a newer Lenze i500 (8400) drive for a future upgrade.
• Eaton/Danfoss Cross-Brand Fix: In a high-rise building's HVAC plant, a large 75 HP Eaton SVX9000 drive failed. The exact drive model was discontinued, and a new Eaton replacement had a lead time of several weeks. Precision Electric identified that the Eaton SVX9000 was built by Danfoss and equivalent to Danfoss's VLT drive. The team found a local supplier with the Danfoss model in stock, installed it as a drop-in replacement, and restored the system within a day. The failed Eaton drive was sent for repair and kept as a spare unit.

Conclusion

Siemens VFDs (the SINAMICS series) are powerful tools for industrial motion control, known for their quality and integration into Siemens automation systems. Alternatives abound from other leading manufacturers that match SINAMICS features, including ABB, Yaskawa, Hitachi, Eaton/Danfoss, and Lenze. Evaluating specific needs (power, performance, environment, connectivity) is key to choosing the right drive. Lead time or familiarity of maintenance teams with a brand are often deciding factors.

Precision Electric offers a one-stop solution: they distribute a range of VFD brands, providing unbiased advice on alternatives, and offer expert repair services to extend the life of existing drives. Their approach involves explaining options in clear terms and backing their work with data and warranties. By leveraging their knowledge of technical specifications, industry standards, and real-world case studies, they help customers make informed decisions that maximize uptime and minimize cost.

If you're looking for alternatives, there are plenty of robust options on the market. If you need support or repairs for a Siemens VFD (or any other drive), Precision Electric is here to assist. Their experience means they have likely seen and solved the problem before. Whether it's selecting a new high-efficiency drive, retrofitting an old panel with modern controls, or reviving a “dead” drive on a critical line, they bring the technical expertise and responsive service to keep facilities running smoothly.

Contact Precision Electric for any VFD needs – from Siemens SINAMICS to any brand under the sun. They will ensure you get the right drive or repair solution, avoiding downtime and boosting productivity.

References

1. Siemens SINAMICS VFD Family Range – Tecnica Industriale Pump Drive Catalog Excerpt (0.12 kW to 85 MW range) – Tecnica Industriale PDF
2. Siemens SINAMICS V20 Brochure – Siemens Industry (power range 0.12–30 kW, features of V20) – Siemens PDF
3. Siemens SINAMICS G120 Catalog – RS Components (power range ~0.55–250 kW, G120 capabilities) – RS Online PDF
4. Siemens Drive Migration Article – Power Electronics News (Jan 2018) (Micromaster to Sinamics replacement, discontinuation timeline) – PowerElectronicsNews
5. Precision Electric – “VFD Repair Services – Cut Downtime & Save Costs” (Jun 2025) – Precision Elec Blog
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