1. Overview: Identifying the PM240-2 Power Module 6SL3210-1PE28-8UL0
The Siemens part number 6SL3210-1PE28-8UL0 identifies a specific SINAMICS G120 PM240-2 Power Module in the FSE mechanical frame size. Decoding the article number yields the following nameplate data:
| Parameter | Specification |
|---|---|
| Product family | SINAMICS G120 Power Module PM240-2 |
| Article number | 6SL3210-1PE28-8UL0 |
| Frame size | FSE |
| Rated power (High Overload, HO) | 37 kW |
| HO overload cycle | 200% for 3 s, 150% for 57 s, 100% for 240 s |
| HO ambient temperature | -20 to +50 °C |
| Rated power (Low Overload, LO) | 45 kW |
| LO overload cycle | 150% for 3 s, 110% for 57 s, 100% for 240 s |
| LO ambient temperature | -20 to +40 °C |
| Supply voltage | 3 AC 380–480 V (+10 % / -20 %) |
| Line frequency | 47–63 Hz |
| Built-in braking chopper | Yes |
| Built-in line filter | No (unfiltered variant) |
| Protection class | IP20 |
| Dimensions (H × W × D) | 551 × 275 × 237 mm |
| Approved Control Unit firmware | V4.7 HF8 |
The trailing designator UL0 in the article number confirms the unfiltered version. This is the variant most commonly supplied for cabinet integration where the EMC architecture is engineered at the panel level. Consequently, an external line filter (or line-side reactor, or both) must be selected to meet the conducted-emissions and harmonic-mitigation requirements of the installation.
Three fundamentally different filter classes are available for this drive, and they are not interchangeable:
- EMC line filter (Class A or Class B) – limits conducted radio-frequency emissions on the line side to meet EN 61800-3.
- Line harmonics filter – reshapes the distorted input current into a near-sinusoidal waveform and reduces the THDi.
- dv/dt filter plus Voltage Peak Limiter (VPL) – protects the motor winding insulation from voltage peaks on long motor cables.
The remainder of this reference covers the selection, sizing, wiring, and commissioning of each filter category for the FSE frame PM240-2.
2. Line Filter Architecture and EMC Categories per EN 61800-3
The Siemens Product Support documentation framework for SINAMICS drives follows the categories of EN 61800-3 (Adjustable speed electrical power drive systems – EMC requirements and specific test methods). For the PM240-2, the relevant categories are:
| Category | Environment | Use case | Filter requirement |
|---|---|---|---|
| C1 | Residential / light-industrial | Connected to public low-voltage supply that also supplies residential buildings | Class B filter required, installation by EMC professional |
| C2 | Industrial | Connected to public low-voltage supply (industrial / commercial mix) | Class A filter required, professional installation and notification |
| C3 | Industrial | Connected exclusively to industrial low-voltage supply (transformer separates from public network) | Class A filter adequate |
| C4 | Industrial, complex | Heavy industrial environment with dedicated transformer and qualified EMC plan | Filter designed into the system |
For the 6SL3210-1PE28-8UL0 (unfiltered PM240-2, FSE), the typical minimum requirement is a Class A line filter when the drive is installed in category C2 or C3 environments. Class B filters are required for category C1 installations (residential or mixed use) and are physically larger and more expensive than Class A equivalents.
3. EMC Class A Line Filter for the FSE Frame
Siemens offers a base line filter in the 6SL3203-0BE series that is mechanically and electrically matched to each PM240-2 frame size. For the FSE frame at 37/45 kW, the recommended base line filter is the FSE-class unit from the 6SL3203-0BE32 series, rated for 250 A continuous line current.
| Filter | Siemens Article Number | Frame | Rated current | Class | Mounting |
|---|---|---|---|---|---|
| Base line filter for FSE (recommended for 6SL3210-1PE28-8UL0) | 6SL3203-0BE32-5SA0 | FSE | 250 A | A (industrial) | Footprint / under-drive or side-mount, refer to mechanical CAD in Siemens support entry 109763155 |
The base line filter must be installed immediately upstream of the power module, with the shortest possible cable between the filter output and the drive input terminals. Siemens specifies a maximum cable length of approximately 1 m between the filter output and the PM240-2 input to maintain the emissions limit; longer lengths will compromise the filter's effectiveness at higher frequencies and may force the installation into a higher EMC category.
3.1 Class A vs Class B Selection
For installations where the PM240-2 is connected to a public low-voltage network supplying residential premises (category C1), a Class B filter is mandatory. Siemens supplies Class B line filters for the PM240-2 via the Schaffner / Epcos family, integrated into the same 6SL3203 family. Because the FSE frame sits in a power class where Class B filters are not always a standard catalog item, the recommendation is:
- For C2/C3 (industrial): use the Class A base line filter 6SL3203-0BE32-5SA0.
- For C1 (residential): consult Siemens for a Class B solution, or place the PM240-2 on a dedicated industrial transformer that reclassifies the installation to C3.
4. Line Harmonics Filter for the PM240-2
The PM240-2 with 6-pulse rectifier input draws a non-sinusoidal current that typically exhibits a THDi of 35–45 %. Where harmonic limits apply (e.g. IEEE 519, EN 61000-3-12, or local utility requirements), a line harmonics filter is added upstream of the EMC line filter. The line harmonics filter is a passive LCL network that reshapes the input current toward sinusoidal and limits the THDi to approximately 5–10 %.
The Siemens support entry 109763155 – Line harmonics filter for SINAMICS G120 Power Module PM240-2 documents the matching table between PM240-2 frame size and the appropriate line harmonics filter variant. The key selection parameters from that entry are summarized below for the FSE frame.
| Parameter | FSE 37/45 kW |
|---|---|
| PM240-2 article numbers covered | 6SL3210-1PE28-8.x, 6SL3210-1PE31-1.x |
| Rated line voltage | 3 AC 380–480 V, 47–63 Hz |
| Rated apparent power (LO) | ~62 kVA at 400 V |
| Rated apparent power (HO) | ~51 kVA at 400 V |
| Filter topology | Passive LCL with integrated capacitors and inductors |
| Typical THDi with filter | ≤ 10 % (typically 5–8 %) |
| Typical THDi without filter | 35–45 % |
| Power loss in filter | ~2–3 % of drive rated power |
| Cooling | Forced-air or natural convection depending on variant; verify against Siemens catalog |
When using a line harmonics filter, the line reactor that is otherwise required for the PM240-2 6-pulse rectifier is typically not installed separately, because the harmonics filter incorporates the necessary inductance. Refer to the wiring diagram in the entry 109763155 to confirm whether the line reactor must be retained, removed, or replaced.
5. dv/dt Filter plus Voltage Peak Limiter (VPL)
Long motor cables (typically > 50 m shielded, > 100 m unshielded) cause voltage reflections at the motor terminals that can reach twice the DC-bus voltage of the drive. The PM240-2 IGBT switching edges at 4–8 kV/µs produce peak voltages that degrade the motor winding insulation. The dv/dt filter plus VPL limits the voltage rise time (dv/dt) to ≤ 500 V/µs and clamps the peak voltage to a safe value, typically ≤ 1500 V.
For the FSE frame at 37/45 kW, Siemens offers matching dv/dt filter + VPL modules that are wired in series with the motor output of the PM240-2. The selection is keyed on the drive's rated output current (≈ 75 A for 37 kW HO, ≈ 90 A for 45 kW LO at 400 V) and the expected motor-cable length.
| Cable length / situation | Required filter | Voltage peak at motor |
|---|---|---|
| < 50 m shielded, < 100 m unshielded | None (standard motor with standard insulation) | ≤ 1000 V |
| 50–150 m shielded | dv/dt filter | ≤ 1500 V (with filter) |
| 150–300 m shielded, or motors with unknown / older insulation | dv/dt filter + VPL | ≤ 1500 V clamped |
| > 300 m, or motors with very old / non-inverter-rated insulation | Sine filter (output filter) | ≈ sinusoidal |
6. Filter Selection Decision Matrix for 6SL3210-1PE28-8UL0
Use the following decision matrix to consolidate the filter requirements for the FSE frame at 37/45 kW.
| Installation scenario | EMC Class A filter | Line harmonics filter | Line reactor | dv/dt filter + VPL | Output sine filter |
|---|---|---|---|---|---|
| Industrial, public LV (C2), motor cable < 50 m | Yes (6SL3203-0BE32-5SA0) | Optional (utility requirement) | Yes, if no harmonics filter | No | No |
| Industrial, public LV (C2), motor cable 50–150 m | Yes | Optional | Yes, if no harmonics filter | dv/dt filter only | No |
| Industrial, public LV (C2), motor cable 150–300 m, motor with standard insulation | Yes | Optional | Yes, if no harmonics filter | dv/dt filter + VPL | No |
| Heavy industrial, dedicated transformer (C3), motor cable < 50 m | Yes | Yes (if THDi limits apply) | No (in harmonics filter) | No | No |
| Residential or mixed (C1) | Class B filter required | Yes (THDi limit) | No (in harmonics filter) | Per cable length | Per cable length |
| HVAC / building services, public LV, motor cable > 100 m | Class B filter | Yes | No | dv/dt + VPL or sine filter | Recommended for > 300 m |
7. Mechanical Installation and Clearances
The base line filter (6SL3203-0BE32-5SA0) and the line harmonics filter for the FSE frame are both designed to be installed in the same cabinet as the PM240-2. Observe the following installation rules:
- Mount the EMC line filter on the line side of the power module, immediately adjacent to the input terminals. Maximum lead length from filter output to drive input: 1 m, kept as short and straight as possible.
- Mount the line harmonics filter upstream of the EMC line filter, leaving at least 100 mm clearance above and below for airflow. Filters dissipate 2–3 % of the drive's rated power as heat; do not install them above heat-sensitive components.
- Maintain a minimum of 50 mm clearance on either side of the PM240-2 for cooling airflow. The drive uses internal forced-air cooling with intake at the front and exhaust at the bottom or top depending on the frame variant; consult the PM240-2 operating instructions for the specific airflow direction in the FSE frame.
- Provide a low-impedance bonding path from the filter housing to the cabinet back-panel and to the drive's PE terminal. Use a short, wide copper braid or stranded conductor of at least 10 mm² (6 AWG) cross-section. The PE conductor carries high-frequency noise and must be kept short; pigtail PE connections will fail EMC testing.
- Route the motor output cables (drive → dv/dt filter → motor) in a dedicated cable channel at least 200 mm away from the line-side cables to avoid capacitive coupling between input and output.
8. Electrical Wiring and Grounding
Use the following conductor cross-sections for the FSE frame, based on the rated input current of approximately 75 A (37 kW HO) or 90 A (45 kW LO) and a 3-phase 400 V supply. Cross-sections are for copper conductors with PVC insulation, routed in a cabinet at 40 °C ambient, and must be adjusted for higher ambient temperatures per IEC 60364-5-52.
| Conductor | Recommended size (Cu) | Notes |
|---|---|---|
| L1, L2, L3 input from utility to harmonics filter | 35 mm² (or 2 × 25 mm² parallel) | Verify against local code and the filter's terminal rating |
| L1, L2, L3 from harmonics filter to EMC filter | 35 mm² | Keep as short as possible |
| L1, L2, L3 from EMC filter to PM240-2 input | 35 mm² | Max 1 m, shielded if > 0.5 m |
| PE (filter housing → cabinet PE bar) | ≥ 16 mm², short copper braid | Low-impedance high-frequency bonding |
| PE (drive PE → cabinet PE bar) | ≥ 16 mm² | Same bonding bar as filter |
| U, V, W from drive to dv/dt filter to motor | 35 mm² (3 × + PE), shielded | Use symmetrically constructed 4-core cable; ground shield at both ends via 360° EMC glands |
8.1 Grounding topology
The filters and the drive must share a single low-impedance ground reference. The recommended topology is a star-ground arrangement on a copper PE bar mounted on the cabinet back-panel:
- Utility PE (incoming ground) → PE bar (single point of entry)
- Line harmonics filter housing → PE bar (shortest braid)
- EMC line filter housing → PE bar (shortest braid)
- PM240-2 PE terminal → PE bar (shortest braid)
- dv/dt filter housing → PE bar (shortest braid)
- Motor frame PE (via motor cable PE conductor) → PE bar
Do not daisy-chain the PE connections from one component to the next. Each high-frequency noise source must have its own direct, low-inductance path back to the PE bar.
9. Commissioning Parameters on the Control Unit (CU)
The PM240-2 6SL3210-1PE28-8UL0 is approved for use with Control Unit firmware V4.7 HF8. After installing any external line filter, the Control Unit must be configured to match the new line-side impedance. The relevant parameters in the SINAMICS G120 parameter list (commissioned via IOP, STARTER, or TIA Portal with the SINAMICS Startdrive G120 G2 / Startdrive V15.1 or later) are:
| Parameter | Description | Recommended setting |
|---|---|---|
| p0220 | Line filter type connected upstream | 0 = No line filter (do not use when external filter is installed) 1 = Line filter present (default for filtered drive variants) Specific values for line harmonics filter are listed in the CU parameter list for V4.7 HF8 |
| p0221 | Line filter capacitance (for active filter detection) | Read-only, set automatically when p0220 is parameterized correctly |
| p0222 | Line filter inductance | Read-only, set automatically when p0220 is parameterized correctly |
| p0223 | Line harmonics filter type | Set per Siemens parameter list for the specific filter variant |
| p0210 | Supply voltage | 400 V (or 380 / 415 / 480 V to match actual utility) |
p0220 will either disable the active filter detection (leaving the drive vulnerable to high inrush currents) or cause nuisance overcurrent trips. Always restore the parameter to the value that matches the filter that is actually wired into the cabinet. Refer to the CU parameter list in the SINAMICS G120 / G120C List Manual for firmware V4.7 HF8 before saving.10. Verification and Acceptance Testing
After mechanical installation, wiring, and parameterization, perform the following verification steps before energizing the motor.
- Visual inspection: Confirm all filter housings are bonded to the PE bar with a low-inductance braid; confirm that all PE conductors are tight to the manufacturer's torque specification.
- Insulation test (megger): With the filters and the drive isolated from the utility, perform a 500 V DC insulation test between each phase conductor and PE. The reading must be ≥ 1 MΩ. Do not megger the filter output while it is connected to the drive's rectifier – the rectifier's input capacitors will charge and may be damaged by the megger's high voltage.
- Phase rotation: Verify L1, L2, L3 rotation matches the drive's input marking. Reverse rotation at the input will not damage the rectifier, but the drive will report a phase-sequence fault (F30022) on first run.
- No-load run with motor decoupled: Run the drive in jog mode at 5 Hz for 30 s with the motor mechanically disconnected. Listen for unusual acoustic noise from the filter inductors, and confirm that the input current drawn from the utility is within ±10 % of the expected no-load current. A current reading significantly above the expected value indicates a wiring error or a damaged filter.
- THDi measurement: With a power-quality analyzer (e.g. Fluke 435, Hioki PW3198, or Siemens Sentron PAC4200) on the utility side of the harmonics filter, measure the THDi at full load. Expected value: ≤ 10 %. The 5th, 7th, 11th, and 13th harmonics should each be individually below the limit specified in EN 61000-3-12 for the installation's short-circuit power ratio Rsce.
- Conducted emissions scan (optional, for EMC compliance): Sweep 150 kHz to 30 MHz with a spectrum analyzer and a line-impedance-stabilization network (LISN). Compare the trace against the EN 61800-3 Class A (or Class B) quasi-peak and average limits. A passing result will show all measured points 10 dB or more below the limit line.
11. Troubleshooting Filter-Related Faults on the FSE PM240-2
The following faults are most frequently traced to filter selection, wiring, or parameter issues on the 6SL3210-1PE28-8UL0.
| Fault code (Fxxxx / Axxxx) | Meaning | Filter-related cause | Action |
|---|---|---|---|
| F30022 | DC-link undervoltage / line phase missing | Filter wired with reversed phase rotation, or filter open-circuit (blown fuse / loose terminal) | Verify L1/L2/L3 rotation; torque input terminals; check filter fuse if present |
| F30021 | DC-link overvoltage | Filter inductance too high combined with regenerative load, or dv/dt filter wired on line side instead of motor side | Confirm dv/dt filter is on U/V/W output; reduce ramp-down rate; check that line harmonics filter is on the line side |
| F30002 | DC-link overvoltage on pre-charge | Filter capacitor pre-charge path not closed; line filter capacitance too high for the drive's pre-charge circuit | Reduce p0220 to the correct filter type; verify that the filter variant matches the one in the parameter list |
| F07801 | Motor overcurrent | dv/dt filter inserted with reversed phase, or dv/dt filter output shorted to PE | Verify dv/dt filter wiring; insulation test U/V/W to PE |
| F07900 | Motor speed deviation | Output sine filter present but not parameterized | Set p0230 = 1 (output filter present) if a sine filter is installed |
| A05001 | Line harmonics filter overtemperature warning | Cabinet ventilation inadequate, or filter undersized for actual load cycle | Check filter fan (if present); verify cabinet cooling; confirm load profile is within the filter rating |
| A05002 | Line harmonics filter capacitance degradation | End-of-life of internal capacitors (typical > 10 years at 40 °C ambient) | Schedule filter replacement; measure individual harmonic levels to confirm degradation |
12. Long-Term Maintenance and Filter Service Life
The expected service life of the line harmonics filter capacitors is typically 100,000 hours at 40 °C ambient, or roughly 11 years of continuous operation. The dv/dt filter has no scheduled service items, but the output terminals and the VPL clamping element should be inspected visually for discoloration or cracking every 2 years. The EMC line filter has no serviceable parts; if it fails (e.g. capacitor rupture after a line-side overvoltage event), replace the entire filter as a unit.
Spare-parts planning for the FSE frame at 37/45 kW should keep at least one EMC line filter and one line harmonics filter (if installed) in stock, as the failure of either will cause a full line-side fault that disables the drive until the part is replaced.
FAQ
What is the correct Siemens line filter part number for the SINAMICS G120 PM240-2 6SL3210-1PE28-8UL0 (37/45 kW, FSE)?
For the FSE frame, the recommended Class A base line filter is 6SL3203-0BE32-5SA0 (250 A). For Class B (residential / C1 environment), consult Siemens for a frame-specific Class B variant, or use a dedicated industrial transformer to reclassify the installation to C3. The matching line harmonics filter is documented in Siemens support entry 109763155.
Does the 6SL3210-1PE28-8UL0 need a line reactor when a line harmonics filter is installed?
No, when a line harmonics filter is installed upstream of the PM240-2, the line reactor is typically not required because the filter integrates the necessary input inductance. The line reactor should be retained only if the drive is operated without the harmonics filter or if a specific Siemens wiring diagram (e.g. in the operating instructions for firmware V4.7 HF8) explicitly requires it for the FSE frame.
How long can the motor cable be when using the PM240-2 6SL3210-1PE28-8UL0 without a dv/dt filter?
Up to 50 m of shielded cable or 100 m of unshielded cable is permitted without a dv/dt filter, provided the motor has standard inverter-rated insulation. Beyond that, install a dv/dt filter (50–150 m shielded) or a dv/dt filter plus VPL (150–300 m). For cables longer than 300 m, use an output sine filter to limit peak voltage and dv/dt at the motor terminals.
Which Control Unit firmware version is approved for the 6SL3210-1PE28-8UL0?
The FSE power module is approved for use with Control Unit firmware V4.7 HF8, as stated in the nameplate data. When a line harmonics filter is installed, parameter p0220 (line filter type) must be set per the parameter list for that firmware, and the drive must be re-commissioned via the IOP, STARTER, or TIA Portal Startdrive tool.
Why does the drive trip with F30022 (DC-link undervoltage / phase failure) immediately after filter installation?
The most common cause is a wiring error between the filter and the drive input: either a phase is missing, a fuse inside the filter has blown, or the phase rotation is reversed. With the drive isolated, perform a continuity check on L1, L2, L3 between the filter output and the drive input, verify the input fuse (if present in the filter), and confirm that L1/L2/L3 rotation matches the drive's input marking before re-energizing.
Is the JTA:TEF1203-0KB mentioned in the original inquiry a line filter or a dv/dt filter?
JTA:TEF1203-0KB is a Siemens internal release / order code covering the dv/dt filter plus Voltage Peak Limiter family for the PM240-2 family, not an EMC line filter. It is used on the motor output side, not the line input side, and is the correct dv/dt filter accessory for long motor-cable applications with the FSE power module.