SIMOTION D4x5

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SIMOTION

SIMOTION D4x5
Commissioning and Hardware Installation Manual
Valid for SIMOTION D425, D435 and D445/D445-1 as
well as the CX32, CBE30 and TB30 supplementary
system components

11/2010

Preface


Description

1

Use planning

2

Installing

3

Connection

4

Commissioning (hardware)

5

Parameter assignment /
addressing

6

Commissioning (software)

7

Service and maintenance

8

Diagnostics

9

Configuration of drive-related
I/Os (without symbolic
assignment)

A

Standards and approvals

B

ESD guidelines

C


Legal information

Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.
CAUTION
without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.
NOTICE
indicates that an unintended result or situation can occur if the corresponding information is not taken into
account.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
Qualified Personnel
The product/system described in this documentation may be operated only by personnel qualified for the specific
task in accordance with the relevant documentation for the specific task, in particular its warning notices and
safety instructions. Qualified personnel are those who, based on their training and experience, are capable of
identifying risks and avoiding potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended
or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be adhered to. The information in the relevant documentation must be observed.
Trademarks
All names identified by are registered trademarks of the Siemens AG. The remaining trademarks in this
publication may be trademarks whose use by third parties for their own purposes could violate the rights of the
owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.

Siemens AG
Industry Sector
Postfach 48 48
90026 NRNBERG
GERMANY


Copyright Siemens AG 2010.
Technical data subject to change

SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 3
Preface
Contents of this commissioning and hardware installation Manual
This document is part of the SIMOTION D documentation package.
Scope
The SIMOTION D4x5 Commissioning and Hardware Installation Manual is valid for the
SIMOTION D425, SIMOTION D435, SIMOTION D445/D445-1, and CX32 devices.
A separate SIMOTION D4x5-2 Commissioning and Hardware Installation Manual is available
for the SIMOTION D4x5-2 devices including the CX32-2 and TB30 system components.
Standards
The SIMOTION system was developed in accordance with ISO 9001 quality guidelines.
Information in this manual
The following is a description of the purpose and use of this Commissioning and Hardware
Installation Manual:
Description
Provides information about the SIMOTION system and its integration in the automation
environment.
Use planning
Provides information on the transport, storage, and environmental conditions.
Installation
Provides information on the various installation options for the device.
Connection
Provides information about connecting and cabling the various devices, and about
communications interfaces.
Commissioning (hardware)
Provides information on commissioning the device.
Parameter assignment / addressing
Provides information on configuring and parameterizing the various bus systems.
Commissioning (software)
Provides information on configuring and commissioning the system.
Preface

SIMOTION D4x5
4 Commissioning and Hardware Installation Manual, 11/2010
Maintenance and servicing
Provides information about service and maintenance procedures that must be performed
on the device.
Diagnostics
Provides information about the available diagnostic information, how to interpret it, and its
meaning.
Appendices with factual information for reference (e.g. standards, approvals and ESD
guidelines).
SIMOTION Documentation
An overview of the SIMOTION documentation can be found in a separate list of references.
This documentation is included as electronic documentation in the scope of delivery of
SIMOTION SCOUT. It comprises 10 documentation packages.
The following documentation packages are available for SIMOTION V4.2:
SIMOTION Engineering System
SIMOTION System and Function Descriptions
SIMOTION Service and Diagnostics
SIMOTION IT
SIMOTION Programming
SIMOTION Programming - References
SIMOTION C
SIMOTION P
SIMOTION D
SIMOTION Supplementary Documentation
Hotline and Internet addresses
Additional information
Click the following link to find information on the the following topics:
Ordering documentation/overview of documentation
Additional links to download documents
Using documentation online (find and search in manuals/information)
http://www.siemens.com/motioncontrol/docu
Please send any questions about the technical documentation (e.g. suggestions for
improvement, corrections) to the following e-mail address:
docu.motioncontrol@siemens.com
Preface

SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 5
My Documentation Manager
Click the following link for information on how to compile documentation individually on the
basis of Siemens content and how to adapt this for the purpose of your own machine
documentation:
http://www.siemens.com/mdm
Training
Click the following link for information on SITRAIN - Siemens training courses for automation
products, systems and solutions:
http://www.siemens.com/sitrain
FAQs
You can find Frequently Asked Questions on the Service&Support pages under Product
Support:
http://support.automation.siemens.com
Technical support
Country-specific telephone numbers for technical support are provided on the Internet under
Contact:
http://www.siemens.com/automation/service&support
Disposal and recycling of the device
SIMOTION D is an environmentally friendly product. It includes the following features:
In spite of its excellent resistance to fire, the flame-resistant agent in the plastic used for
the housing does not contain halogens.
Identification of plastic materials in accordance with DIN 54840.
Less material used because the unit is smaller and with fewer components thanks to
integration in ASICs.
The disposal of the products described in this manual should be performed in compliance
with the valid national regulations.
The products can be largely recycled owing to their low pollutant content. To recycle and
dispose of your old device in an environmentally friendly way, please contact a recycling
company certified for electronic waste.
If you have any further questions about disposal and recycling, please contact your local
Siemens representative. Contact details can be found in our contacts database on the
Internet at:
http://www.automation.siemens.com/partner/index.asp
Preface

SIMOTION D4x5
6 Commissioning and Hardware Installation Manual, 11/2010
Further information / FAQs
You can find further information on this manual under the following FAQs:
http://support.automation.siemens.com/WW/view/de/27585482
You can also find additional information under:
SIMOTION Utilities & Applications: SIMOTION Utilities & Applications will be included in
the SIMOTION SCOUT scope of delivery and, along with FAQs, also contain free utilities
(e.g. calculation tools, optimization tools, etc.) as well as application examples (ready-to-
apply solutions such as winders, cross cutters or handling).
The latest SIMOTION FAQs at
http://support.automation.siemens.com/WW/view/en/10805436/133000
SIMOTION SCOUT online help
Refer to the list of references (separate document) for additional documentation

SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 7
Table of contents

Preface...................................................................................................................................................... 3
1 Description............................................................................................................................................... 13
1.1 System overview..........................................................................................................................13
1.2 System components ....................................................................................................................17
1.3 I/O integration...............................................................................................................................22
1.4 Commissioning software..............................................................................................................23
1.5 Safety notes .................................................................................................................................24
2 Use planning............................................................................................................................................ 25
2.1 Shipping and storage conditions..................................................................................................25
2.2 Mechanical and climatic ambient conditions................................................................................26
2.3 Information on insulation tests, safety class, and degree of protection.......................................29
3 Installing .................................................................................................................................................. 31
3.1 Installation notes ..........................................................................................................................31
3.2 Installing the SIMOTION D4x5.....................................................................................................31
3.3 Side-mounting of SIMOTION D4x5 on SINAMICS assembly......................................................34
3.4 Mounting SIMOTION D4x5 on the wall of the control cabinet .....................................................35
3.4.1 Mounting the SIMOTION D4x5 with spacers...............................................................................35
3.4.2 Mounting SIMOTION D425, D435, and D445-1 without spacers................................................37
3.5 Installing supplementary system components.............................................................................38
3.5.1 Installing the TB30 .......................................................................................................................38
3.5.2 Installing the CBE30 ....................................................................................................................39
3.5.3 Installing the CX32.......................................................................................................................40
3.5.4 Removing the cover of the CX32.................................................................................................45
4 Connection .............................................................................................................................................. 47
4.1 Complete overview (example) .....................................................................................................47
4.2 Safety information for wiring ........................................................................................................49
4.3 Opening the front cover ...............................................................................................................50
4.4 Power supply................................................................................................................................51
4.4.1 Safety rules ..................................................................................................................................51
4.4.2 Standards and Regulations..........................................................................................................52
4.4.3 Mains voltage...............................................................................................................................52
4.4.4 Connecting the power supply.......................................................................................................53
4.5 Connecting DRIVE-CLiQ components.........................................................................................54
4.5.1 DRIVE-CLiQ wiring ......................................................................................................................54
4.5.2 Connectable DRIVE-CLiQ components.......................................................................................56
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4.5.3 Connecting CX32........................................................................................................................ 58
4.6 Connecting inputs/outputs........................................................................................................... 62
4.6.1 Creating a shield connection....................................................................................................... 63
4.6.2 Connecting inputs/outputs of the TB30....................................................................................... 64
4.7 Connecting PROFIBUS/MPI ....................................................................................................... 66
4.7.1 PROFIBUS connection components........................................................................................... 66
4.7.2 PROFIBUS cables and connectors............................................................................................. 67
4.7.3 PROFIBUS cable lengths............................................................................................................ 67
4.7.4 Rules for the laying of PROFIBUS cables .................................................................................. 68
4.7.5 Connecting PROFIBUS DP (interfaces X126 and X136) ........................................................... 68
4.7.6 Connection rules in the PROFIBUS subnet ................................................................................ 69
4.7.7 Operating the X136 interface as MPI.......................................................................................... 71
4.8 Connecting PROFINET IO components ..................................................................................... 73
4.8.1 Wiring PROFINET....................................................................................................................... 73
4.8.2 PROFINET cable ........................................................................................................................ 74
4.9 Routing........................................................................................................................................ 76
4.9.1 Routing on SIMOTION D ............................................................................................................ 76
4.9.2 Routing on SIMOTION D (SINAMICS integrated) ...................................................................... 79
4.10 Connecting Ethernet ................................................................................................................... 80
4.10.1 Wiring Ethernet ........................................................................................................................... 80
4.10.2 Ethernet cables and connectors ................................................................................................. 80
5 Commissioning (hardware) ...................................................................................................................... 83
5.1 Requirements for commissioning................................................................................................ 83
5.1.1 Inserting the CompactFlash card................................................................................................ 83
5.1.2 Checking the system................................................................................................................... 85
5.1.3 Switching on the power supply ................................................................................................... 85
5.2 RESET button ............................................................................................................................. 87
5.3 User memory concept ................................................................................................................. 88
5.3.1 SIMOTION D4x5 memory model ................................................................................................ 88
5.3.2 Properties of the user memory.................................................................................................... 89
5.3.3 Operations and their effect on the user memory......................................................................... 93
5.4 Fan ............................................................................................................................................ 100
5.4.1 Cooling the SIMOTION D4x5.................................................................................................... 100
5.4.2 Fan/battery module on the D425/D435..................................................................................... 101
5.4.3 Fan/battery module on the D445/D445-1.................................................................................. 101
5.4.4 Overview of states, fan/battery module..................................................................................... 103
5.4.5 Response to overtemperature .................................................................................................. 105
6 Parameter assignment / addressing ...................................................................................................... 107
6.1 Software requirements.............................................................................................................. 107
6.2 Creating a project and configuring communication................................................................... 107
6.2.1 Creating a SIMOTION project and inserting a D4x5................................................................. 107
6.2.2 Configuring the PROFIBUS PG/PC interface ........................................................................... 110
6.2.3 Configuring the Ethernet PG/PC interface................................................................................ 111
6.2.4 Representation of SIMOTION D4x5 in HW Config................................................................... 113
6.3 Configuring PROFIBUS DP ...................................................................................................... 114
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6.3.1 General information about communication via PROFIBUS DP.................................................114
6.3.2 Operating SIMOTION D4x5 on PROFIBUS DP. .......................................................................115
6.3.3 Assignment of the PROFIBUS addresses in HW Config...........................................................117
6.3.4 Setting the DP cycle and system cycle clocks...........................................................................118
6.3.5 Cycle clock scaling of external PROFIBUS interface to internal PROFIBUS interface.............119
6.3.6 Creating a new PROFIBUS subnet ...........................................................................................121
6.3.7 Modifying the data transmission rate.........................................................................................122
6.3.8 Establishing a PG/PC assignment .............................................................................................123
6.4 Configuring an Ethernet subnet .................................................................................................124
6.4.1 Configuring an MPI bus .............................................................................................................124
6.4.1.1 Operating the X136 interface as MPI.........................................................................................124
6.4.1.2 MPI parameters .........................................................................................................................124
6.4.2 Properties of the Ethernet interfaces .........................................................................................125
6.4.3 Configuring Ethernet addresses in HW Config..........................................................................127
6.4.4 Reading out IP and MAC address .............................................................................................128
6.5 Configuring PROFINET IO.........................................................................................................129
6.5.1 General information about communication via PROFINET IO..................................................129
6.5.2 Setting a send cycle clock and a system cycle clock.................................................................132
6.5.3 Properties of PROFINET ...........................................................................................................133
6.5.4 Configuration tasks ....................................................................................................................134
7 Commissioning (software) ..................................................................................................................... 135
7.1 Overview of commissioning .......................................................................................................135
7.1.1 Symbolic assignment / adaptation.............................................................................................135
7.1.2 Procedure when commissioning................................................................................................139
7.1.3 Important functions for the project handling during commissioning...........................................140
7.2 Performing offline configuration for the D4x5 ............................................................................141
7.2.1 Overview....................................................................................................................................141
7.2.2 Accessing the drive wizard ........................................................................................................142
7.2.3 Configuring components............................................................................................................143
7.2.4 Downloading a project into the target system............................................................................161
7.2.5 Downloading a project to the CF card .......................................................................................163
7.2.6 Loading a project, including sources and additional data..........................................................164
7.2.7 Archiving a project to the CompactFlash Card (zip file) ............................................................165
7.3 Performing online configuration for D4x5 ..................................................................................166
7.3.1 Overview....................................................................................................................................166
7.3.2 Establish an online connection ..................................................................................................167
7.3.3 Starting the automatic configuration ..........................................................................................168
7.3.4 Editing SINAMICS components.................................................................................................172
7.3.5 Downloading a project to SIMOTION D4x5...............................................................................172
7.4 Configuring a CX32....................................................................................................................174
7.4.1 Overview....................................................................................................................................174
7.4.2 Basic principles of the CX32......................................................................................................174
7.4.3 Preparing for configuration.........................................................................................................176
7.4.4 Displaying the topology..............................................................................................................179
7.4.5 Performing CX32 configuration offline.......................................................................................180
7.4.5.1 Loading a project created offline to the target system...............................................................181
7.4.5.2 Loading a project created offline to the CF card........................................................................182
7.4.6 Performing CX32 configuration online.......................................................................................183
7.4.7 CX32 configuration instructions .................................................................................................184
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7.4.7.1 CX32 power-up ......................................................................................................................... 184
7.4.7.2 Interconnecting the infeed "Operation" signal on the CX32...................................................... 185
7.4.7.3 CX32 diagnostics ...................................................................................................................... 187
7.4.7.4 Upgrading D4x5/CX32 .............................................................................................................. 188
7.4.7.5 Replacing D4x5/CX32............................................................................................................... 189
7.5 Additional information on configuring the SINAMICS Integrated.............................................. 190
7.5.1 Settings for DP slave properties ............................................................................................... 190
7.5.2 Using vector drives.................................................................................................................... 191
7.5.3 Setting the time of day .............................................................................................................. 194
7.5.4 SINAMICS diagnostic buffer ..................................................................................................... 197
7.5.5 Acyclic communication with the drive ....................................................................................... 197
7.5.6 Control properties and performance features ........................................................................... 198
7.5.7 Current controller cycle clocks <> 125 s / use of output cams and measuring inputs............ 199
7.6 Testing a drive with the drive control panel............................................................................... 200
7.7 Creating and testing axes ......................................................................................................... 203
7.7.1 Overview of SIMOTION engineering ........................................................................................ 203
7.7.2 Creating an axis with the axis wizard........................................................................................ 204
7.7.3 Testing the axis with the axis control panel .............................................................................. 211
7.8 Activating the infeed (line module)............................................................................................ 213
7.8.1 Infeed without DRIVE-CLiQ connection.................................................................................... 214
7.8.2 Infeeds with DRIVE-CLiQ connection....................................................................................... 214
7.9 Setting up addresses and message frames.............................................................................. 216
7.9.1 Setting up communication for symbolic assignment ................................................................. 216
7.9.2 Message frame configuration.................................................................................................... 216
7.10 Linking an additional encoder (optional) ................................................................................... 219
7.10.1 Fundamentals ........................................................................................................................... 219
7.10.2 Additional encoders on the drive............................................................................................... 220
7.10.3 Additional encoders via PROFIBUS/PROFINET...................................................................... 221
7.11 Symbolic assignment of I/O variables (PROFIdrive message frame / drive parameters) ........ 222
7.11.1 Symbolic assignment of I/O variables to the PROFIdrive message frame of the TO axis ....... 222
7.11.2 Symbolic assignment of I/O variables to drive parameters....................................................... 222
7.12 Configuration of drive-related I/Os (with symbolic assignment)................................................ 226
7.12.1 Configuration of the I/O terminals ............................................................................................. 227
7.12.1.1 Configuration of the D4x5 I/Os (terminal X122/X132) .............................................................. 228
7.12.1.2 Configuration of the CX32/CU3xx/TB30/TMxx I/O terminals.................................................... 229
7.13 Configuration of the technology objects and I/O variables ....................................................... 230
7.13.1 Configuration of global measuring inputs.................................................................................. 230
7.13.2 Configuration of local measuring inputs.................................................................................... 231
7.13.3 Configuration of output cams / cam tracks................................................................................ 231
7.13.4 Configuration of the I/Os (variables / TO axis).......................................................................... 234
7.14 DMC20/DME20 DRIVE-CLiQ hub ............................................................................................ 235
7.14.1 Hub properties........................................................................................................................... 235
7.14.2 Creating a DMC20/DME20 DRIVE-CLiQ hub........................................................................... 236
7.15 TM41 Terminal Module ............................................................................................................. 236
7.15.1 Overview ................................................................................................................................... 236
7.15.2 Configuring TM41 at SINAMICS Integrated.............................................................................. 237
7.15.3 Configuring TM41 using the Axis Wizard.................................................................................. 238
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7.16 Optimizing drive and closed-loop controller...............................................................................238
7.16.1 Overview of automatic controller setting....................................................................................238
7.16.2 Automatic speed controller setting.............................................................................................239
7.16.3 Automatic position controller setting..........................................................................................240
7.16.4 Measuring functions, trace, and function generator...................................................................242
7.16.5 Manual speed controller optimization ........................................................................................243
7.17 Downloading and storing user data ...........................................................................................247
7.18 Deleting data..............................................................................................................................249
7.18.1 Overview of data deletion ..........................................................................................................249
7.18.2 Overall reset of SIMOTION D4x5 ..............................................................................................249
7.18.3 Deleting user data from CF card................................................................................................252
7.18.4 Restoring the default settings of SINAMICS Integrated ............................................................253
7.18.5 Setting SIMOTION D4x5 to the default settings ........................................................................253
7.19 Powering down the system........................................................................................................254
7.20 Configuring Safety Integrated functions.....................................................................................254
7.21 Migration D445 to D445-1..........................................................................................................259
7.21.1 Overview....................................................................................................................................259
7.21.2 Configuration..............................................................................................................................260
7.21.3 Compatibility...............................................................................................................................260
8 Service and maintenance ...................................................................................................................... 263
8.1 Overview....................................................................................................................................263
8.2 Replacing modules (spare part scenario) ..................................................................................267
8.2.1 Parts replacement for SIMOTION D4x5 ....................................................................................267
8.2.2 Removal and replacement of the SIMOTION D4x5...................................................................268
8.2.3 Replacing DRIVE-CLiQ components.........................................................................................269
8.2.4 Replacing the CompactFlash Card............................................................................................272
8.3 Adapting a project (Updating the project / Replacing the SIMOTION controller) ......................272
8.3.1 Overview....................................................................................................................................272
8.3.2 Creating backup copies (project/CF) .........................................................................................273
8.3.3 Backing up user data (backup variables)...................................................................................273
8.3.4 Upgrading a user project to the new SCOUT version................................................................275
8.3.5 Platform replacement via XML export/import.............................................................................276
8.3.6 Preparing the device replacement .............................................................................................277
8.3.7 Device replacement in HW Config.............................................................................................279
8.3.8 Upgrading technology packages................................................................................................279
8.3.9 Upgrading the device version of SINAMICS S120 control units................................................282
8.3.10 Upgrading a library.....................................................................................................................283
8.3.11 Save project, compile and check consistency ...........................................................................284
8.4 Performing a firmware and project update.................................................................................284
8.4.1 Upgrading the CompactFlash Card's boot loader......................................................................284
8.4.2 Update - preparatory measures.................................................................................................285
8.4.3 Update via IT DIAG....................................................................................................................286
8.4.4 Upgrade via device update tool (upgrading SIMOTION devices)..............................................286
8.4.5 Upgrade via CF card..................................................................................................................291
8.4.5.1 Backup of the CF card data .......................................................................................................291
8.4.5.2 Firmware upgrade via CF card ..................................................................................................292
8.4.5.3 Upgrading SINAMICS................................................................................................................293
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8.4.5.4 Loading a project to the target system...................................................................................... 294
8.5 SIMOTION Compact Flash card............................................................................................... 295
8.5.1 Changing the CompactFlash Card............................................................................................ 295
8.5.2 Writing to the the CompactFlash card....................................................................................... 296
8.5.3 Formatting the CompactFlash card........................................................................................... 297
8.5.4 Bootloader on the CompactFlash card ..................................................................................... 297
8.5.5 Recommended method for dealing with CF cards.................................................................... 298
8.5.6 Card reader for CF cards .......................................................................................................... 298
9 Diagnostics............................................................................................................................................ 299
9.1 Diagnostics via LED displays.................................................................................................... 299
9.1.1 SIMOTION D4x5 and SINAMICS Integrated displays.............................................................. 300
9.1.2 LED displays of the PROFINET interface................................................................................. 306
9.1.3 LED displays of the Ethernet interface...................................................................................... 307
9.1.4 LED displays of the CX32 controller extension......................................................................... 308
9.1.4.1 Behavior of the LEDs during booting of the CX32.................................................................... 308
9.1.4.2 Behavior of the LEDs after booting of the CX32....................................................................... 309
9.2 Diagnostic data and non-volatile data....................................................................................... 310
9.2.1 Overview ................................................................................................................................... 310
9.2.2 Backing up diagnostic data and non-volatile data .................................................................... 310
9.2.2.1 Diagnostic data ......................................................................................................................... 310
9.2.2.2 Non-volatile data (retain data)................................................................................................... 311
9.2.2.3 Procedure for backing up during operation............................................................................... 311
9.2.2.4 Procedure for backing up during startup................................................................................... 312
9.2.2.5 Storing data............................................................................................................................... 314
9.2.3 Diagnostics via websites........................................................................................................... 315
9.2.4 Deleting/restoring non-volatile data .......................................................................................... 317
9.2.5 Backing up diagnostic data and non-volatile data using IT DIAG............................................. 318
9.3 Additional service and diagnostics options ............................................................................... 320
9.3.1 SIMOTION Task Profiler application......................................................................................... 320
9.3.2 Diagnostics using IT DIAG........................................................................................................ 321
A Configuration of drive-related I/Os (without symbolic assignment)......................................................... 323
A.1 Local and global measuring inputs ........................................................................................... 323
A.2 Configuring local measuring inputs........................................................................................... 325
B Standards and approvals....................................................................................................................... 327
B.1 General rules............................................................................................................................. 327
B.2 Safety of electronic controllers.................................................................................................. 329
C ESD guidelines ...................................................................................................................................... 331
C.1 ESD definition ........................................................................................................................... 331
C.2 Electrostatic charging of individuals.......................................................................................... 332
C.3 Basic measures for protection against discharge of static electricity ....................................... 333
Index...................................................................................................................................................... 335

SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 13
Description 1
1.1 System overview
Overview
SIMOTION D is a drive-based version of SIMOTION based on the SINAMICS S120 drive
family.
With SIMOTION D, the SIMOTION PLC and motion control functionalities as well as the
SINAMICS S120 drive software run on shared control hardware.
SIMOTION D is available in two versions:
SIMOTION D410 is a compact control unit for single-axis applications and is snapped on
to the SINAMICS S120 PM340 power module in blocksize format.
SIMOTION D4x5 is a control unit for multi-axis applications in SINAMICS S120 booksize
format and is offered in several performance variants:
SIMOTION D425 (BASIC performance) for up to 16 axes
SIMOTION D435 (STANDARD performance) for up to 32 axes
SIMOTION D445/D445-1 (HIGH Performance) for up to 64 axes
Compared with SIMOTION D445, SIMOTION D445-1 offers an improvement in PLC
and motion control performance of approximately 30%, depending on the application.
Consequently, SIMOTION D445-1 is the preferred solution for new applications as of
V4.1 SP2.
This manual describes the SIMOTION D4x5 for multi-axis applications. Separate manuals
are available for the SIMOTION D410 single-axis module as well as for the SIMOTION
D4x5-2 multi-axis modules.
Like SINAMICS S120, SIMOTION D also follows the Totally Integrated Automation (TIA)
concept. TIA is characterized by integrated data management, configuration, and
communication for all products and systems. Thus, an extensive toolbox of automation
modules is also available for SIMOTION D.

Note
In order to cover all versions of SIMOTION D for multi-axis applications, the product will be
referred to as "D4x5". Specific product designations will be used for information that applies
only to one product version, e.g. D435.

Description
1.1 System overview
SIMOTION D4x5
14 Commissioning and Hardware Installation Manual, 11/2010
Application
SIMOTION D4x5 is ideally suited to applications with many coordinated axes with high clock-
pulse rates.
Typical applications include:
Compact multiple-axis machines
High-performance applications with short machine cycles
Compact machines
Including the complete machine control in the drive
With extensive connection possibilities for communication, HMI and I/O
Distributed drive concepts
Applications with many axes
Synchronization of several SIMOTION D control units using distributed synchronous
operation
Versions
The individual versions - SIMOTION D425 (BASIC Performance), SIMOTION D435
(STANDARD Performance) and SIMOTION D445/D445-1 (HIGH Performance) - differ in
terms of their PLC performance and motion control performance. The main distinguishing
features are:

SIMOTION D425 SIMOTION D435 SIMOTION D445/D445-1
Maximum number of axes 16 32 64
Minimum servo/interpolator
cycle clock
2.0 ms 1.0 ms 0.5 ms
DRIVE-CLiQ interfaces 4 4 6

SIMOTION D4x5 features PLC and motion control performance (open-loop control and
motion control) for up to 16, 32 or 64 axes, as required.
Due to the following functional improvements, we recommend using a SIMOTION D445-1
instead of a SIMOTION D445 for new applications as of V4.1 SP2:
An increase of around 30% in PLC and motion control performance, depending on the
application
Less mounting depth (mounting is possible even without spacers)
Double-fan/battery module for higher availability
Further information (http://support.automation.siemens.com/WW/view/en/31507782)
The computing functions integrated into the drive allow the D4x5 control unit to operate up to
six servo, four vector or eight V/f axes.
Description
1.1 System overview
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 15
The drive control supports servo control (for a highly dynamic response), vector control (for
maximum torque accuracy) and V/f control.

Note
With the SIZER configuration tool, you can easily configure the SINAMICS S120 drive family
including SIMOTION.
It provides you with support for selecting and dimensioning the components required for a
motion control task.
You can also determine the possible number of axes and the resulting load with SIZER in
accordance with your performance requirements.

Hardware components
As the central hardware, SIMOTION D uses the SIMOTION D4x5 as a control unit consisting
of the SIMOTION runtime system and the SINAMICS drive control. The control unit uses the
SINAMICS Integrated drive with various SINAMICS S120 drive modules (line and motor
modules) to perform open-loop and closed-loop control of the axis grouping. A range of
additional SINAMICS S120 components, such as SMx encoder systems or terminal modules
can be connected via DRIVE-CLiQ. With a few exceptions (e.g. no basic positioner EPOS,
no basic operator panel BOP20, etc.), the drive control integrated in SIMOTION D has the
same control characteristics and performance features as the SINAMICS S120 CU320
control unit. The EPOS functionality is provided by the SIMOTION technology functions. The
functionality of SIMOTION D can be expanded with the distributed I/O via PROFIBUS or with
the CBE30 Ethernet communication board via PROFINET IO.
The following figure shows a typical SIMOTION D axis grouping.
DRlVE-CLiQ l/O devices
(Terminal modules)
DRlVE-CLiQ
DRlVE-CLiQ
Power

Figure 1-1 Example of a SIMOTION D4x5 axis assembly
Description
1.1 System overview
SIMOTION D4x5
16 Commissioning and Hardware Installation Manual, 11/2010
A SIMOTION D axis grouping generally consists of the following elements:
SIMOTION D (control unit) (1)
This unit contains the programmable runtime system of SIMOTION and the drive software
of SINAMICS S120. In principle, SIMOTION D is capable of controlling multiple
axes/drives.
One SINAMICS infeed (line module) (2)
This module generates a DC link from the supply system.
SINAMICS power units (motor modules) (3)
These modules are used to control motors.
It is also possible to operate SINAMICS PM340 power modules with the SINAMICS
control unit adapter (CUA). A separate infeed is then unnecessary.
DRIVE-CLiQ components (4)
In SINAMICS S120 / SIMOTION D, the individual components of the drive system
communicate with each other via DRIVE-CLiQ. In addition to power components,
encoder systems and special DRIVE-CLiQ I/O devices can also be linked via
DRIVE-CLiQ.
Extension of the drive computing performance
The motion control performance of a SIMOTION D4x5 can be utilized in full by expanding
the computing performance at the drive in two different ways:
SINAMICS S110/S120 control units complete with further SINAMICS S110/120 drive
modules can be connected via PROFIBUS or PROFINET.
With SIMOTION D435 and D445/D445-1, the CX32 controller extension can be
connected via DRIVE-CLiQ. This module is extremely compact and can control up to
six servo, four vector or eight V/f axes.
Software components
The basic functionality of SIMOTION D is supplied on a CompactFlash card containing the
following:
The SIMOTION runtime system with the following functions:
Freely programmable runtime system (IEC 61131)
Various runtime levels (tasks)
PLC and arithmetic functionality
Motion control functions
Communication functions
The SINAMICS S120 drive control with the following functions:
Closed-loop current and torque control
Closed-loop speed control
Regulated infeed
Description
1.2 System components
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 17
1.2 System components
Central components
SIMOTION D4x5 communicates with automation components via the following interfaces:
PROFIBUS DP
Ethernet
PROFINET IO (when using a CBE30)
DRIVE-CLiQ (DRIVE Component Link with IQ).
SIMOTION D features a SINAMICS Integrated drive element. Communication with the
SINAMICS Integrated is via PROFIBUS mechanisms (DP Integrated).
The most important components of the system and their functions are shown below.
Table 1- 1 Central components
Component Function
SIMOTION D4x5 controller ... is the central motion control module.
This module contains the programmable SIMOTION runtime for the
SIMOTION D4x5 and the SINAMICS S120 drive software.
You can use the integrated high-speed digital I/Os as:
Homing inputs
Inputs for measuring inputs
User-addressable process inputs/outputs
Outputs for fast output cams
The measuring sockets can output any analog signals.
System software The basic functionality of SIMOTION D is supplied on a CompactFlash
card containing the following:
SIMOTION runtime (kernel)
Drive software of SINAMICS S120 - implements all drive functions
Power supply ... provides the electronic power supply for SIMOTION D, e.g. via the
SITOP power supply.
Description
1.2 System components
SIMOTION D4x5
18 Commissioning and Hardware Installation Manual, 11/2010
PROFIBUS DP
The control unit can communicate with the following components via the PROFIBUS DP
interfaces:
Table 1- 2 Components on PROFIBUS DP
Component Function
Programming device (PG/PC) ... configures, parameterizes, programs, and tests with the
"SIMOTION SCOUT" engineering system (ES)
SIMATIC HMI device ... is used for operating and monitoring functions. This is not an
essential requirement for the operation of a control unit.
Other controllers (e.g.
SIMOTION or SIMATIC)
.. e.g. higher-level controller (plant controller); modular machine
concepts with multiple controls, distributed across individual machine
modules
Distributed I/O systems
SIMATIC ET 200M Modular I/O system for control cabinet installation and high channel
density
SIMATIC ET 200S Finely scalable I/O system for control cabinet configuration and
particularly time-critical applications; including motor starters, safety
technology and individual grouping of load groups
SIMATIC ET 200pro Modular I/O system with IP65/67 degree of protection for machine-
related applications with no control cabinet; with features such as
compact designs, integrated PROFIsafe safety technology,
PROFINET connection and live module replacement.
SIMATIC ET 200eco I/O system with IP65/67 degree of protection for cabinet-free use
close to the machine with flexible and fast ECOFAST or M12
connection methods
Other PROFIBUS I/O
Gateways
DP/AS-Interface link 20E and DP/AS-Interface link Advanced for
the PROFIBUS DP gateway to AS-Interface
DP/DP coupler for connecting two PROFIBUS DP networks
Drive interfaces
ADI4 (Analog Drive Interface for 4 axes) for connection of drives
with analog 10 V setpoint interface or for external encoders
IM174 (Interface Module for 4 axes) for connection of drives with
analog 10 V setpoint interface, for external sensors, or for
connection of stepper drives with pulse-direction interface
Drive units with
PROFIBUS DP interface (e.g.
SINAMICS S120)
... convert speed setpoints into signals for controlling the motor and
supply the power required to operate the motors.
Also can be operated as an isochronous slave on PROFIBUS DP.
Teleservice adapter Remote diagnostics
Description
1.2 System components
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 19
Ethernet
The control unit can communicate with the following components via the Ethernet interfaces
or be embedded in an automation environment:
Table 1- 3 Components on the Ethernet
Component Function
Programming device (PG/PC) ... configures, parameterizes, programs, and tests with the
"SIMOTION SCOUT" engineering system (ES)
Master computer ... communicates with other devices via UDP, TCP/IP
SIMATIC HMI device ... is used for operating and monitoring functions. This is not an
essential requirement for the operation of a control unit.
PROFINET IO
The use of a Communication Board Ethernet (CBE30) enables SIMOTION D4x5 to
communicate with the following components via PROFINET IO:
Table 1- 4 Components on the PROFINET IO
Component Function
Programming device (PG/PC) ... configures, sets parameters, programs and tests using the
"SIMOTION SCOUT" Engineering System (ES).
SIMATIC HMI device ... is used for operating and monitoring functions. This is not an
essential requirement for the operation of a control unit.
Other controllers (e.g.
SIMOTION or SIMATIC)
... e.g. higher-level controller (plant controller); modular machine
concepts with multiple controls, distributed across individual
machine modules
Master computer ... communicates with other devices via UDP, TCP/IP.
Distributed I/O systems
SIMATIC ET 200M Modular I/O system for control cabinet installation and high
channel densities.
SIMATIC ET 200S Finely scalable I/O system for control cabinet installation and
particularly time-critical applications; including motor starters,
safety technology and individual grouping of load groups.
SIMATIC ET 200pro Modular I/O system with IP65/67 degree of protection for machine-
related applications with no control cabinet; with features such as
compact designs, integrated PROFIsafe safety technology,
PROFINET IO connection and live module replacement.
SIMATIC ET 200eco PN Compact block I/O with IP65/66/67 degree of protection for
cabinet-free usage in machines with M12 connection method. Very
rugged and resistant encapsulated metal enclosure.
Other PROFINET IO I/O devices
Drive units with PROFINET IO
interface
... convert speed setpoints into signals for controlling the motor
and supply the power required to operate the motors.
Gateways
IE/AS-Interface link PN IO for the PROFINET IO gateway to
AS-Interface
PN/PN coupler for connecting two PROFINET IO networks
Description
1.2 System components
SIMOTION D4x5
20 Commissioning and Hardware Installation Manual, 11/2010
DRIVE-CLiQ
The DRIVE-CLiQ interfaces permit a fast connection to the SINAMICS drive components.
DRIVE-CLiQ offers the following advantages within the DRIVE-CLiQ topology rules:
Expandability of components
Automatic detection of components by the control unit
Standardized interfaces to all components
Uniform diagnostics down to the components
Complete service down to the components
Simple mechanical handling
The controller can communicate with the following components via DRIVE-CLiQ:
Table 1- 5 Components connected to DRIVE-CLiQ
Component Function
Control unit
(SINAMICS S110/S120)
Central control module in which the open- and closed-loop
control functions for the drive are implemented.
Line module (SINAMICS S120) ... generates a DC link from the supply system.
Motor module (SINAMICS S120) ... used to control motors (DC/AC inverters, booksize).
Power module (SINAMICS
S110/S120)
...used to control motors (AC/DC converters, blocksize).
CX32 controller extension ... enables additional axes to be connected for SIMOTION D435
and D445/D445-1.
CUA31/CUA32 control unit
adapter
...enables a blocksize power module (PM340) to be connected to
a booksize control unit D4x5, CX32 or CU320.
TM31 terminal module ... enables a terminal expansion via DRIVE-CLiQ (additional
analog and digital I/Os).
TM41 terminal module ... enables a terminal expansion (analog and digital I/Os) and
encoder simulation.
TM54F terminal module ... enables terminal expansion (secure digital inputs/outputs) for
controlling the secure motion monitoring functions of the
integrated drives.
TM15, TM17 High Feature
terminal module
The terminal modules TM15 and TM17 High Feature are used to
implement inputs of measuring inputs and outputs of cam
outputs. In addition, these terminal modules provide drive-related
digital inputs and outputs with short signal delay times.
SMx sensor modules ... enable acquisition of encoder data from connected motors via
DRIVE-CLiQ.
Motors with DRIVE-CLiQ
interface
...allow simplified commissioning and diagnostics, as the motor
and encoder type are identified automatically.
DMC20/DME20 DRIVE-CLiQ hub enables the number of DRIVE-CLiQ interfaces to be increased
and the creation of a star-shaped topology.
Description
1.2 System components
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 21


Note
You can find detailed information about components in the SINAMICS S110/S120 family of
products in the SINAMICS S110/S120 manuals.

Optional components
The functionality of the D4x5 control unit can be expanded by using one of the components
listed below.
Table 1- 6 Optional components
Component Function
Communication Board Ethernet
CBE30
Communication via PROFINET IO with IRT and PROFINET IO
with RT
Terminal Board TB30 Terminal expansion, i.e. additional analog and digital I/Os
The selected component is plugged into the option slot of the control unit.
Description
1.3 I/O integration
SIMOTION D4x5
22 Commissioning and Hardware Installation Manual, 11/2010
1.3 I/O integration

Note
Note that not all modules in the ET 200 I/O family are approved for SIMOTION. Moreover,
system-related functional differences can come into play when these I/O or I/O systems are
used on SIMOTION vs. on SIMATIC. For example, special process-control functions (e.g.,
HART modules, etc.) are not supported by SIMOTION for the ET 200M distributed I/O
system.
A detailed, regularly updated list of the I/O modules approved for use with SIMOTION, as
well as notes on their use, can be found on the Internet at
(http://support.automation.siemens.com/WW/view/en/11886029):

In addition to the I/O modules enabled for SIMOTION, in principle all certified standard
PROFIBUS slaves (DP-V0/DP-V1/DP-V2) and PROFINET IO devices with RT and IRT real-
time classes may be connected to SIMOTION D4x5. These modules are integrated using the
GSD file (PROFIBUS) or GSDML file (PROFINET) provided by the relevant device
manufacturer.

Note
Please note that in individual cases further boundary conditions must be fulfilled in order to
integrate a standard slave/standard device into SIMOTION. Thus, a few modules require
"driver blocks" , e.g., in the form of function blocks, that permit (or simplify) integration.
For modules enabled for SIMOTION (e.g. SIMATIC S7-300 module FM 350-1, etc.), these
driver modules are part of the SIMOTION SCOUT Engineering System command library.

Description
1.4 Commissioning software
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 23
1.4 Commissioning software
Requirement
To create and edit projects on your PG/PC, you need the SIMOTION SCOUT commissioning
and configuration tool. For information on how to install SIMOTION SCOUT, refer to the
SIMOTION SCOUT Configuration Manual.

Note
SIMOTION SCOUT contains the functionality of STARTER and SIMATIC S7-Technology.
Simultaneous operation of SIMOTION SCOUT, STARTER and SIMATIC S7-Technology as
a single installation on one PC/PG is not possible.

Integrated starter
You can insert a standalone drive (e.g. SINAMICS S120) with the "Insert single drive unit"
element in the project navigator. It is commissioned using wizards in the working area of the
workbench that contains the STARTER functionality.
SINAMICS Support Package (SSP)
You can use a SINAMICS Support Package (SSP) to upgrade the version of the drive units
on a STARTER integrated into SIMOTION SCOUT.
This permits the use of new functions which only become available with new drive unit FW
versions.
In this regard, the following SSPs are relevant for SIMOTION SCOUT:
"SINAMICS" SSP for upgrading single drive units (e.g. CU3xx)
"SIMOTION SINAMICS Integrated" SSP for upgrading the SINAMICS drives integrated
into SIMOTION D.
Detailed installation instructions appear in the Readme files supplied with each each SSP.
Upgrade SIMOTION D4x5 projects and hardware
Projects that you have created for one SIMOTION D4x5 firmware version can also be
converted for other firmware versions. Furthermore, you can amend the version of
SIMOTION D4x5. For example, a D425 can be converted to a D435 (and vice versa, insofar
as the performance and quantity structure allow this). For further information, see Section
Adapting a project (Updating the project / Replacing the SIMOTION controller) (Page 272).
Description
1.5 Safety notes
SIMOTION D4x5
24 Commissioning and Hardware Installation Manual, 11/2010
IT DIAG
The SIMOTION D4x5 features an integrated web server.
The web server supports the display of diagnostics and system data in standard Internet
browsers, even in the absence of an engineering system, and the carrying out of
project/firmware updates.
As of firmware version V4.2, it is no longer necessary to purchase licenses for SIMOTION IT
DIAG and SIMOTION IT OPC XML-DA.
Additional references
For detailed information on working with projects, refer to the SIMOTION SCOUT
Configuration Manual.
For detailed information about IT DIAG, see the
SIMOTION IT Ethernet-based HMI and Diagnostic Functions Diagnostics Manual.
1.5 Safety notes
Note the following safety information when working with the control unit and its components.

NOTICE
The 80 mm clearances above and below the components must be observed. The unit
protects itself from overheating by shutting down.

CAUTION
An option board may only be inserted and removed when the control unit and option board
are disconnected from the power supply.
The Compact Flash card may only be inserted or removed when the control unit is
disconnected from the power supply.
The SIMOTION D4x5 is in a de-energized state when all the LEDs are OFF.



SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 25
Use planning 2
2.1 Shipping and storage conditions
Shipping and storage conditions
With regard to transportation and storage conditions, SIMOTION D4x5 surpasses the
requirements specified in IEC 1131, Part 2. The following conditions apply to modules that
are transported and stored in the original packaging.
Conditions
Table 2- 1 Shipping and storage conditions
Type of condition Permissible range
Free fall 1 m
Temperature From -40 C to +70 C
Atmospheric pressure Air pressure in mbar (kPa):
> 700 mbar (70 kPa)
< 1060 mbar (106 kPa)
The specified values correspond to a transport or storage altitude of up
to 3,000 m.
Relative humidity 5% to 95%, without condensation
Shipping backup batteries
If possible, ship the backup batteries in the original packaging. No special measures are
required to ship backup batteries used for SIMOTION D. The lithium content of the backup
battery is less than 0.5 g.
Use planning
2.2 Mechanical and climatic ambient conditions
SIMOTION D4x5
26 Commissioning and Hardware Installation Manual, 11/2010
Storage of backup batteries
Always store backup batteries in a cool and dry place. The batteries have a maximum shelf
life of 10 years.

WARNING
Risk of injury, material damage, release of hazardous substances.
Do not throw new or discharged batteries into a fire and do not solder the cell body (max.
temperature 100 C) and also do not recharge the batteries - there is an explosion hazard!
Do not open a battery. Replace a faulty battery only with the same type.
Only use a replacement from Siemens (for order number, see manual).
Always try to return old batteries to the manufacturer or deliver these to a registered
recycling company.

Note
If you have a spare parts inventory, you must not store a SIMOTION D4x5 with the
fan/battery module mounted. Only connect the fan/battery module if the fan or battery
backup voltage is required.

2.2 Mechanical and climatic ambient conditions
Conditions of use
SIMOTION D4x5 is designed for use in stationary, weather-protected locations. The
operating conditions surpass the IEC 1131-2 requirements.
SIMOTION D4x5 satisfies the operating conditions for Class 3C3 in accordance with DIN EN
607213-3 (operating locations with high traffic densities and in the immediate vicinity of
industrial equipment with chemical emissions).
Use prohibition
Without additional measures, SIMOTION D4x5 may not be used in
Locations with a high percentage of ionizing radiation
Locations with extreme operating conditions, e.g.
Dust accumulation
Corrosive vapors or gases
In systems, which require special monitoring, e.g.
Elevator installations
Electrical installations in highly sensitive areas
Use planning
2.2 Mechanical and climatic ambient conditions
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 27
An additional measure for using SIMOTION D4x5 can, for example, be installation in
cabinets.
Mechanical ambient conditions
SIMOTION D4x5 meets the following standards for mechanical stress:
Vibrational load: DIN EN 60721-3-3, Class 3M4
Shock load: DIN EN 60721-3-3, Class 3M4
Free fall: DIN EN 60721-3-2, Class 2M1 and Class 2M2
Toppling: DIN EN 60721-3-2, Class 2M1
The mechanical ambient conditions for SIMOTION D4x5 are listed in the following table in
the form of sinusoidal vibrations.
Table 2- 2 Mechanical ambient conditions
Frequency range (Hz) continuous infrequent
10 f 58 0.0375 mm amplitude 0.075 mm amplitude
58 f 150 0.5 g constant acceleration 1 g constant acceleration
Vibration reduction
If SIMOTION D4x5 is subjected to larger shocks or vibrations, you must use suitable
measures to reduce the acceleration or the amplitude.
We recommend installation on shock-absorbing material (e.g. rubber-metal vibration
dampers).
Testing mechanical environmental conditions
Table 2- 3 Mechanical ambient conditions
Testing Test standard Comments
Vibrations Vibration testing in
accordance with IEC 68
Part 2-6 (sine) severity
level 12
Type of vibration: Frequency sweeps at a rate of
change of 1 octave per minute.
10 Hz f 58 Hz, const. Amplitude 0.075 mm
58 Hz f 500 Hz, const. acceleration 1 g
Duration of vibration: 10 frequency cycles per axis in
each of the 3 perpendicular axes
Shock Shock testing in
accordance with
IEC 68 Part 2-27
Type of shock: half sine
Severity of shock: 15 g peak value, duration = 11 ms
Direction of shock: 3 shocks each in +/- direction in
each of the 3 perpendicular axes
Use planning
2.2 Mechanical and climatic ambient conditions
SIMOTION D4x5
28 Commissioning and Hardware Installation Manual, 11/2010
Climatic ambient conditions
SIMOTION D4x5 satisfies the climatic environmental conditions for Class 3K5 in accordance
with DIN EN 60721-3-3.
SIMOTION D4X5 may not be used under the following climatic ambient conditions:

Ambient conditions Application range Comments
The fan/battery module is optional for SIMOTION
D425 and D435 (Type 6AU1 435-0AA00-0AA1).
The fan/battery module is required at supply air
temperatures of 43 C and above for
SIMOTION D435 (Type 6AU1 435-0AA00-0AA0,
previous version).
A fan/battery module is always
required for SIMOTION D445/D445-1.
Temperature: Vertical
mounting position:
From 0 C to 55 C
The maximum supply air temperature for all
modules is 55 C.
Relative humidity 5% to 95% Without condensation, corresponds to relative
humidity (RH) severity level 2 in accordance with
IEC 1131-2
Atmospheric pressure 700 hPa to 1060 hPa 3000 m - 0 m above mean sea level
Pollutant concentration
SO2: < 0.5 ppm;
Relative humidity < 60%, no
condensation
H2S: < 0.1 ppm;
Relative humidity < 60%, no
condensation
Test:
10 ppm; 4 days

1 ppm; 4 days
Use planning
2.3 Information on insulation tests, safety class, and degree of protection
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 29
2.3 Information on insulation tests, safety class, and degree of
protection
Test voltages
During the routine test, the insulation resistance is tested at the following test voltage in
accordance with IEC 1131 Part 2:
Table 2- 4 Test voltages
Circuits with rated voltage Ue relative to other circuits or
ground
Test voltage
0 V < Ue 50 V 500 VDC
Class of protection
Safety class I in accordance with VDE 0106, Part 1 (IEC 536), i.e. a protective-conductor
terminal is required on the mounting rail.
Protection against ingress of solid foreign bodies and water
Degree of protection IP 20 in accordance with IEC 529, i.e., protection against contact with
standard probes.
Also: Protection against ingress of solid foreign bodies with diameters greater than 12.5 mm.
No special protection against ingress of water.
Use planning
2.3 Information on insulation tests, safety class, and degree of protection
SIMOTION D4x5
30 Commissioning and Hardware Installation Manual, 11/2010

SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 31
Installing 3
3.1 Installation notes
Open equipment
These modules are open equipment. This means they may only be installed in housings,
cabinets, or in electrical equipment rooms that can only be entered or accessed with a key or
tool. Housings, cabinets, or electrical equipment rooms may only be accessed by trained or
authorized personnel. An external fire-protection housing is required.

DANGER
The equipment must be deenergized when you install the control unit.

3.2 Installing the SIMOTION D4x5
Requirement
The control unit is installed in a control cabinet along with the SINAMICS components.
The following requirements must be met for installing a control unit:
The control cabinet has been installed and wired.
SINAMICS components should already have been installed and wired (for side
mounting).
Components and tools are available.
Designs
The control unit is compatible with the SINAMICS S120 in booksize format. There are two
possible mounting methods:
Side mounting on the SINAMICS S120 line module
In this type of installation, the control unit is attached to the side panel of the line module
in the control cabinet.
Direct installation on the wall of the control cabinet
In the case of both designs, the CompactFlash Card and the option slot can be accessed
from the outside. The fan/battery module can be mounted later.
Because the Control Unit is similar to the SINAMICS S120 family with regard to installation,
please follow the instructions in the SINAMICS manuals.
Installing
3.2 Installing the SIMOTION D4x5
SIMOTION D4x5
32 Commissioning and Hardware Installation Manual, 11/2010
Mounting and installation aids
The Control Unit is designed for mounting in a control cabinet (IP20 degree of protection). All
versions of SIMOTION D4x5 are supplied with pre-assembled spacers for installation on the
wall of the control cabinet. The spacers can be removed from the SIMOTION D425, D435,
and D445-1 if necessary.
Cutouts for side mounting
Spacer (optional)
Spacer (optional)

Figure 3-1 Mounting aids based on the example of SIMOTION D425 and D435
Installing
3.2 Installing the SIMOTION D4x5
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 33
Mounting a SIMOTION D445
Because a SIMOTION D445 has cooling ribs for heat dissipation on its rear, the spacers
provided as standard cannot be disassembled.
The D445 can be mounted on the control cabinet wall using spacers or on the side of the
SINAMICS assembly using mounting fixtures.

Note
SIMOTION D445 can only be operated with a fan/battery module. This module is supplied
with SIMOTION D445 and has to be mounted first. A description of how to install the
fan/battery module can be found in the SIMOTION D4x5 Manual (Chapter "Spare
parts/Accessories", Section "Installing the fan/battery module").

See also
Side-mounting of SIMOTION D4x5 on SINAMICS assembly (Page 34)
Mounting the SIMOTION D4x5 with spacers (Page 35)
Mounting SIMOTION D425, D435, and D445-1 without spacers (Page 37)
Installing
3.3 Side-mounting of SIMOTION D4x5 on SINAMICS assembly
SIMOTION D4x5
34 Commissioning and Hardware Installation Manual, 11/2010
3.3 Side-mounting of SIMOTION D4x5 on SINAMICS assembly
The SIMOTION D425, D435, and D445 Control Units can be mounted on the side wall of a
SINAMICS S120 Line Module. The mounting fixtures required for this are supplied with the
SINAMICS S120 Line Module.

Note
Assembly on the side of the SINAMICS S120 Line Module using 5 mounting fixtures is not
possible with SIMOTION D445-1.
SIMOTION D445-1 must always be screwed to the control cabinet wall.

The SINAMICS S120 Line Module has five mounting fixtures on the left side. To mount the
control unit, proceed as follows:
1. Attach the Control Unit to the left side of the SINAMICS S120 Line Module. The mounting
fixtures fit exactly in the five cutouts on the module.
2. Push the two units together.
3. Press down on the module until the unit engages and is securely connected to the
SINAMICS S120 Line Module.
The module is connected flush with the SINAMICS assembly on top and in front.

Figure 3-2 SINAMICS assembly with SIMOTION D4x5
Installing
3.4 Mounting SIMOTION D4x5 on the wall of the control cabinet
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 35
3.4 Mounting SIMOTION D4x5 on the wall of the control cabinet
Overview
If you need to or wish to remove the Line Module, the Control Unit can also be mounted on
the wall of the control cabinet. Two mounting options are provided for mounting on the wall
of the control cabinet:
Mounting with spacers on the wall of the control cabinet (all D4x5)
Mounting without spacers on the wall of the control cabinet (D425/D435/D445-1 only)
D445-1 next to Line Module
If you wish to install a SIMOTION D445-1 directly to the left of a Line Module, you will need
to remove the plastic mounting fixtures from the side wall of the Line Module.
These mounting fixtures stick out over the side wall of the Line Module.
SIMOTION D445-1 has a smooth wall (i.e. there are no cut-outs on the side). so can only be
installed flush next to the Line Module if the mounting fixtures on the Line Module are
removed.
Proceed as follows to do this:


1. Use suitable tools to lift the latching
device and push up the holder.
2. Remove the holder View of the side wall once the holder has
been removed
3.4.1 Mounting the SIMOTION D4x5 with spacers
Spacers enable you to attach the Control Unit to a bare, conductive metallic wall of a control
cabinet with two M5 or M6 screws.
Purpose of this type of installation
This type of mounting is needed if:
Multiple Control Units are to be used and, therefore, all Control Units cannot be mounted
on the side
The mounting depth of the SINAMICS S120 booksize assembly is to be achieved
Installing
3.4 Mounting SIMOTION D4x5 on the wall of the control cabinet
SIMOTION D4x5
36 Commissioning and Hardware Installation Manual, 11/2010
The spacers are included in the scope of delivery of a Control Unit and are ready-
assembled.
Procedure
1. Mount the spacers on the D425/D435/D445-1 Control Unit, if they have previously been
removed.
2. Use two M5 or M6 screws to mount the Control Unit on the wall of the control cabinet.
Mounting with
M5 or M6 screws
Mounting with
M5 or M6 screws
Cooling fins
Example D425/D435 Example D445

Figure 3-3 Mounting the control unit with spacers
Result
The Control Unit is mounted separately from the SINAMICS booksize components and flush
with the assembly on the wall of the control cabinet.
Installing
3.4 Mounting SIMOTION D4x5 on the wall of the control cabinet
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 37
3.4.2 Mounting SIMOTION D425, D435, and D445-1 without spacers
The control unit has a metal clip at the top of the rear panel; when shipped, the clip is
pushed in and secured with three M3 screws (0.8 Nm).
1. Loosen the screws and push the clip up until the upper hole extends beyond the housing.
2. Tighten up the three screws on the clip again.
3. Mount the Control Unit directly on the wall of the control cabinet at the top and bottom
using two M5 or two M6 screws (6 Nm tightening torque).
Mount with
M5 or M6 screws

Figure 3-4 Mounting the Control Unit on the wall of the control cabinet
The Control Unit is mounted separately from the SINAMICS booksize components on the
wall of the control cabinet.
Installing
3.5 Installing supplementary system components
SIMOTION D4x5
38 Commissioning and Hardware Installation Manual, 11/2010
3.5 Installing supplementary system components
3.5.1 Installing the TB30
Requirement

Note
The TB30 terminal board may only be inserted and removed when the D4x5 control unit and
the terminal board are de-energized.

Procedure
The TB30 is installed in the option slot of the control unit.
1. Release and remove
the cover
Fixing screws
M3 / 0.8 Nm
Torx T10
2. lnsert and fix
the option board

Figure 3-5 TB30 terminal board installation
Installing
3.5 Installing supplementary system components
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 39
3.5.2 Installing the CBE30
Requirement

Note
The CBE30 communication board Ethernet may only be inserted and removed when the
D4x5 control unit and the CBE30 are de-energized.

Procedure
A CBE30 is installed in the option slot of the control unit.
1. Unscrew and remove the
protective cover
Mounting screws
M3/0.8 Nm
Torx T10
2. lnsert and secure
the option board

Figure 3-6 Installing the CBE30
Installing
3.5 Installing supplementary system components
SIMOTION D4x5
40 Commissioning and Hardware Installation Manual, 11/2010
3.5.3 Installing the CX32
Overview
The CX32 can be installed in several ways.
Mounting the CX32 directly on a line module in booksize format

Figure 3-7 Mounting the CX32 directly on a line module booksize
Installing
3.5 Installing supplementary system components
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 41
Mounting the CX32 on another CX32
A description with photos of opening the cover can be found in Section Removing the cover
of the CX32 (Page 45).
Table 3- 1 Mounting a CX32 on another CX32
Opening the covers. Unscrewing the screw. The bracket must be moved so
that the pin is in the opening of
the bracket. Tighten the screw.
Installing
3.5 Installing supplementary system components
SIMOTION D4x5
42 Commissioning and Hardware Installation Manual, 11/2010

Mounted bracket. Closing the cover.
Installing
3.5 Installing supplementary system components
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 43
CX32 directly on a mounting surface
There are two mounting points on the rear side of the CX32. These can be screwed directly
to a wall, e.g a control cabinet wall.
Secure with
screws
(M6 / 6 Nm)

Figure 3-8 Mounting the CX32 directly on a mounting surface
Installing
3.5 Installing supplementary system components
SIMOTION D4x5
44 Commissioning and Hardware Installation Manual, 11/2010
CX32 with spacers on a mounting surface
To provide the correct mounting depth for a booksize line-up with internal air cooling, a
spacer element is pre-assembled on the CX32. The spacer must then be fixed to the
mounting surface.
Spacers

Figure 3-9 Mounting a CX32 with spacers
Installing
3.5 Installing supplementary system components
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 45
3.5.4 Removing the cover of the CX32
Actions to remove the cover of the CX32
The following steps are required to remove the cover - see the following photos:
- Release
- Swing open through approx. 45
- Remove
Note that the cover can only be removed when it has been swung open through approx. 45.
Installing
3.5 Installing supplementary system components
SIMOTION D4x5
46 Commissioning and Hardware Installation Manual, 11/2010
Release
Remove
Open

Figure 3-10 Opening/removing the protective cover

SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 47
Connection 4
4.1 Complete overview (example)
Overview
The SIMOTION D4x5 has a number of interfaces that can be used for connecting the power
supply and for communication with the other components of the system. To make these
connections, the front cover of the SIMOTION D4x5 must be opened.
The different SINAMICS components are interconnected via DRIVE-CLiQ.
Actuators and sensors can be connected to the digital inputs/outputs.
For communication purposes, the SIMOTION D4x5 can be connected to PROFIBUS DP,
PROFINET IO with IRT/RT, MPI, and Ethernet.
Connection
4.1 Complete overview (example)
SIMOTION D4x5
48 Commissioning and Hardware Installation Manual, 11/2010
Overview of connections
The following overview shows examples of the various interfaces and their connection
possibilities.
{
X109
X126
X136
X120
X130
X105
X104
X103
X102
X101
X100
X122
X132
X125
X135
PROFlNET lO
lRT/RT l/O
DRlVE-
CLiQ interfaces
PROFlNET lO
CBE30
(optional)
X1400 (4 ports)
e.g. SlNAMlCS S120/CBE20,
ET 200S, ET 200pro
(D445/
D445-1 only)
Digital l/O
HMl, PG, ES
HMl, PG, ES
HMl, PG, ES
USB memory stick
HMl, PG, ES
lM 174 lnterface
Module
SlMATlC ET 200
e.g. ET 200M
PROFlBUS DP
SlMATlC ET 200
e.g. ET 200M
ADl4 Analog Drive
lnterface
PROFlBUS DP drive,
e.g. SlNAMlCS CU320
or
SlNAMlCS CU310
SlMOTlON CF
PROFlBUS DP
interfaces
Ethernet
interfaces
USB
interfaces
SlNAMlCS S120
Line Module
SlNAMlCS S120
Motor Module
Controller Extension
SlMOTlON CX32
Digit. l/O
PROFlBUS DP drive,
e.g. SlNAMlCS CU320
or
SlNAMlCS CU310
Alternatively, MPl/DP

Figure 4-1 Connection possibilities for SIMOTION D4x5
Connection
4.2 Safety information for wiring
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 49
4.2 Safety information for wiring
Requirement
Once you have mounted the control unit in the control cabinet, you can begin wiring the
assembly.

Note
Safety functions, reliability, and EMC are guaranteed only with original SIEMENS cables.

Note the following safety information:

DANGER
The equipment must be deenergized when you wire the control unit.

Equipotential bonding
The SIMOTION D4x5 is designed for use in cabinets with a PE conductor connection.
If the drive line-up is arranged on a common, bare metallic mounting plate (e.g. with a
galvanized surface), no additional equipotential bonding is needed within the drive line-up.
If the drive components are located in different cabinets, you have to ensure equipotential
bonding.
If, for example, data cables (PROFIBUS, PROFINET, Ethernet or DRIVE-CLiQ) are routed
through several control cabinets, the "potential connection" of the SIMOTION D4x5 should
be connected to the equipotential bonding conductor.
Use a finely stranded copper conductor with 4 mm cross section and lay it together with the
PROFIBUS/PROFINET/Ethernet or DRIVE-CLiQ connecting cable.
The "potential connection" is located below the mode switch on the front of the
SIMOTION D4x5. See also the SIMOTION D4x5 Manual.
Connection
4.3 Opening the front cover
SIMOTION D4x5
50 Commissioning and Hardware Installation Manual, 11/2010
4.3 Opening the front cover
Introduction
The interfaces on the front side of the D4x5 and the CX32 have a cover. This is opened by
swinging the front cover down; the interface connections are then accessible and can be
wired. For the opening procedure, see also the photos in Section Removing the cover of the
CX32 (Page 45).
A hinge connects the front cover to the front of the housing. Once opened, the cover can be
removed. The front cover is closed by swinging it up; it automatically locks by means of a
hook at the top of the device housing.
Procedure for D4x5 and CX32
1. Unlatch the release hook on the inside of the front cover (see the following figure).
2. Remove the front cover with a forward motion.

Hooks
Pivoting hinge

Figure 4-2 D4x5 with cover, figure similar for CX32

Note
All cables must be routed vertically upwards to the fullest extent possible so that the front
cover can be closed. The front cover has an outlet for the upward routing of these cables.

Connection
4.4 Power supply
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 51
4.4 Power supply
4.4.1 Safety rules
Basic rules
Because of the wide range of possible applications, only the basic rules for electrical
installation can be included in this section. At a minimum, you must comply with these basic
rules to ensure problem-free operation.
Rules for safe operation
In order to ensure safe operation of your equipment, implement the following measures,
adapting them to suit your conditions:
An EMERGENCY STOP strategy in accordance with the generally accepted rules of
current engineering practice (e.g. European Standards EN 60204, EN 418 and similar).
Additional measures for end position limiting of axes (e.g. hardware limit switches).
Equipment and measures for protection of motors and power electronics in accordance
with the SINAMICS installation guidelines.
In order to identify hazards, we also recommend that a risk analysis be conducted on the
entire system in accordance with the basic safety requirements set out in Appendix 1 of
the EU machinery directive.
Additional references
Guidelines on Handling Electrostatically Sensitive Devices (ESD), see Appendix.
For configuring a system with SIMATIC ET 200 I/O (e.g. ET 200S, ET 200M, ...), refer to
the manuals for the relevant ET 200 I/O system.
For further information on EMC guidelines, we recommend the publication: EMC
Installation Guide, Configuration Manual (HW), order no.: 6FC5 297-0AD30-0AP2.
Connection
4.4 Power supply
SIMOTION D4x5
52 Commissioning and Hardware Installation Manual, 11/2010
4.4.2 Standards and Regulations
VDE guideline compliance
During wiring, you must observe the appropriate VDE guidelines, in particular VDE 0100 and
VDE 0113 for tripping devices and short-circuit and overload protection.
System startup after certain events:
The following list identifies considerations required for startup of a system following certain
events.
If the system starts up again following a voltage drop or power failure, all hazardous
operating states must be prevented from occurring. If necessary, force an EMERGENCY
OFF.
If the system starts up again after the EMERGENCY OFF apparatus is released, the
startup must not be unchecked or undefined.
4.4.3 Mains voltage
Rules for the line voltage
The following list indicates what you must take into account for the line voltage:
For stationary installations or systems that do not have all-pole line disconnect switches,
the building installation must include a line disconnect switch or a fuse.
For load power supplies and power supply modules, the rated voltage range set must
correspond to the local line voltage.
For all circuits, the fluctuation/deviation of the line voltage from the rated value must be
within the permitted tolerance (see the technical data for the SIMOTION D and
SINAMICS modules).
24 V DC supply

For... Requirement
Buildings External lightning
protection
Install lightning protection (e.g.
lightning conductors).
24 V DC supply lines, signal lines Internal lightning
protection

24 V supply safe (electrical) isolation of the extra-low voltage
Connection
4.4 Power supply
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 53
Protection against external electrical phenomena
The table below shows how you must protect your system against electrical interference or
faults.
Table 4- 1 External electrical phenomena
For ... Requirement
All plant or systems in which the
component is installed
The plant or system is connected to a protective
conductor for the discharge of electromagnetic
interference.
Supply, signal, and bus lines The wiring arrangement and installation complies with
EMC regulations.
Signal and bus lines A cable or wire break cannot lead to undefined states in
the plant or system.
4.4.4 Connecting the power supply
Wiring the screw terminal block
The required 24 VDC load power supply is connected at the screw-type terminal block.

DANGER
The 24 VDC should be configured as functional extra-low voltage with safe isolation.

Supply system lines
Use flexible cables with a cross section of 0.25 to 2.5 mm
2
(or AWG 23 to AWG 13) for wiring
the power supply.
If you only use one wire per connection, a ferrule is not required.
You can use ferrules without an insulating collar in accordance with DIN 46228, Form A long
version.
Pin assignments
For the pin assignment of the screw-type terminal block, see the SIMOTION D4x5 Manual.
Connection
4.5 Connecting DRIVE-CLiQ components
SIMOTION D4x5
54 Commissioning and Hardware Installation Manual, 11/2010
4.5 Connecting DRIVE-CLiQ components
4.5.1 DRIVE-CLiQ wiring
Introduction
The components of the SINAMICS S120 drive family and the SIMOTION D4x5 with CX32
are wired together by means of DRIVE-CLiQ. DRIVE-CLiQ is a communication system that
enables SIMOTION D4x5 to detect the connected components automatically. It provides a
wiring tree whose topology can be visualized in SIMOTION SCOUT.

Note
For information on the number of DRIVE-CLiQ interfaces and their properties, refer to the
SIMOTION D4x5 Manual.

Rules for wiring DRIVE-CLiQ
The following rules must be followed for wiring DRIVE-CLiQ:
Ring wiring is not permitted
Components must not be double-wired
For a motor module, the power line for the motor and the associated motor encoder must
be connected.
You will find detailed information about DRIVE-CLiQ wiring in the SINAMICS S120 Control
Units and Additional System Components Manual.
Connection
4.5 Connecting DRIVE-CLiQ components
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 55
Example
The example shown in this diagram shows the rules for DRIVE-CLiQ wiring.
X100
SMCxx
X500
X520
S
l
M
O
T
l
O
N

D
X200...X202
Active
Line
Module
Single
Motor
Module
Single
Motor
Module
X500
X501
X500
X501
TMxx TMxx
DRlVE-CLiQ
DRlVE-CLiQ
X200...X202 X200...X202
No ring wiring
speed
Rotor position
Temperature
Motor
Motor with DRlVE-CLiQ
interface
No double wiring

Figure 4-3 DRIVE-CLiQ wiring (example)
Connection
4.5 Connecting DRIVE-CLiQ components
SIMOTION D4x5
56 Commissioning and Hardware Installation Manual, 11/2010
4.5.2 Connectable DRIVE-CLiQ components
Components
As a general principle, all SINAMICS components approved for SIMOTION D can be
connected directly to SIMOTION D or another DRIVE-CLiQ component using the
DRIVE-CLiQ interface.
Table 4- 2 DRIVE-CLiQ
Component Description
CX32 controller extension The CX32 supports scaling of the drive-side computing performance of
the SIMOTION D435 and D445/D445-1. Each CX32 can operate up to
six additional servo, four vector or eight V/f axes.
Line modules Line modules (e.g. active line modules) provide the DC link voltage and
can be connected via DRIVE-CLiQ depending on the module type.
Motor modules Motor modules are used to control motors. SMC modules for
processing encoder signals, for example, can be connected to motor
modules.
Motors with DRIVE-CLiQ
interface
Motors with a DRIVE-CLiQ interface allow simplified commissioning
and diagnostics, because the motor and encoder type are identified
automatically.
SMx modules SMx sensor modules allow the acquisition of encoder data from the
connected motors via DRIVE-CLiQ.
TM15 and TM17 High
Feature terminal modules
The TM15 and TM17 High Feature terminal modules are used to
implement measuring input inputs and cam outputs. In addition, these
terminal modules provide drive-related digital inputs and outputs with
short signal delay times.
TM15: 24 isolated bidirectional DI/DO, with sensor and cam
functionality
TM17 High Feature: 16 non-floating, bidirectional DI/DO with sensor
and cam functionality for the highest demands with respect to
resolution, accuracy and short input delay times.
TM31 terminal module TM31 provides 8 DI, 4 bidirectional DI/DO, 2 relay outputs, 2 AI, 2 AO
and 1 temperature sensor input (KTY84-130 or PTC).
TM41 terminal module TM41 provides 4 DI, 4 bidirectional DI/DO, 1 AI and 1 TTL encoder
output.
TM54F terminal module TM54F provides the following interfaces: 4 fail-safe DO (F-DO), 10 fail-
safe DI (F-DI), 2 sensor power supplies with dynamic capability, 1
sensor power supply without dynamic capability and 4 DI to check the
F-DO during a test stop.
Connection
4.5 Connecting DRIVE-CLiQ components
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 57
Component Description
DMC20/DME20 DRIVE-CLiQ hubs provide 4 more DRIVE-CLiQ interfaces. They can be
used, for example, to establish star topologies.
DMC20 is the hub for the control cabinet configuration
DME20 is the hub for use without a control cabinet (IP67 degree of
protection)
SINAMICS S120 power
module
(with CUA31/CUA32)
An AC DRIVE PM340 power module can be connected using the
CUA31/CUA32 control unit adapter.
You will find more information on the CUA31/CUA32 in the
SINAMICS S120 AC Drive Manual.
Example of axis assembly
The following figure shows a possible DRIVE-CLiQ wiring scheme for an axis grouping.
SMCxx
X500
X520
S
l
M
O
T
l
O
N

D
X200...X202
Active
Line
Module
Single
Motor
Module
Single
Motor
Module
X500
X501
X500
X501
SMCxx
X500
X520
X200...X202 X200...X202
DRlVE-CLlQ
DRlVE-CLlQ
DRlVE-CLlQ
X100
TMxx TMxx
speed
Rotor position
Temperature
Motor Motor

Figure 4-4 Axis assembly with DRIVE-CLiQ
Connection
4.5 Connecting DRIVE-CLiQ components
SIMOTION D4x5
58 Commissioning and Hardware Installation Manual, 11/2010
4.5.3 Connecting CX32
Installation/Mounting/Wiring
Information on installing, mounting and wiring the CX32 can be found in the SIMOTION
D4x5 Manual.
Connection
4.5 Connecting DRIVE-CLiQ components
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 59
CX32 DRIVE-CLiQ topology
Unlike other DRIVE-CLiQ components (e.g. terminal modules), special rules apply when
wiring the CX32.
Only a star topology is possible between the CX32 and SIMOTION D. Each CX32 needs
its own DRIVE-CLiQ port on the SIMOTION D control unit.
When a CX32 is inserted in an existing DRIVE-CLiQ connection (destination port for
CX32 is occupied by, for example, a TM31), this connection is disconnected and replaced
by the CX32 connection. The component that is freed up is moved to the component
archive of the SINAMICS topology overview. A notice is displayed indicating that the
component has been moved to the archive. The components must then be reassigned.
A CX32 is inserted via HW Config (see Configuring a CX32 (Page 174)). Here, the
selection made for the PROFIBUS address automatically and permanently assigns the
DRIVE-CLiQ port for connecting the CX32. Given that this assignment is permanent, the
following points must be noted:
A connected and configured CX32 cannot be connected to another DRIVE-CLiQ port
without taking additional measures. Reconnecting a CX32 results in a discrepancy
between the specified and actual topologies of the DRIVE-CLiQ components.
A cross-exchange of two occupied DRIVE-CLiQ ports is not permissible. Such an
exchange results in inconsistencies in the specified-actual topologies.
Once it has been created in HW Config, the connecting port of a CX32 cannot be
changed.
In order to change the connecting port of a CX32, the CX32 must be deleted from HW
Config and recreated with another address.
In order to delete a CX32, it must be deleted from HW Config before the configuration
can be saved and compiled.
It is not possible to replace a D445/D445-1 module with a D435 if a CX32 has been
configured with the address 14 or 15 (since a D435 does not have DRIVE-CLiQ ports
X104/X105, it does not have addresses 14 and 15).


Note
Connection possibility
A CX32 can only be connected to and operated on a SIMOTION D445/D445-1 or
D435.
Connection
4.5 Connecting DRIVE-CLiQ components
SIMOTION D4x5
60 Commissioning and Hardware Installation Manual, 11/2010
DRlVE-CLiQ
components
CX32 (1)
DP address 15
DRlVE-CLiQ
components of the
Control Unit
DP address 14
SlMOTlON
D445/D445-1
DRlVE-CLiQ
components
CX32 (2)
CX32 (2)
CX32 (1)
X
1
0
0
X
1
0
5
X
1
0
4
X
1
0
1
X
1
0
2
X
1
0
3
X
1
0
0
X
1
0
1
X
1
0
2
X
1
0
3
X
1
0
0
X
1
0
1
X
1
0
2
X
1
0
3
X
1
2
6
X
1
3
6

Figure 4-5 CX32 topology
Drive quantity structures
If one or more CX32 modules are being used on a SIMOTION D435 or D445/D445-1, the
number of drives that can be used on the SINAMICS Integrated is reduced by one. This
results in the following quantity structures:
SIMOTION V4.1 and V4.2/SINAMICS V2.5 and 2.6
Table 4- 3 Quantity structure SIMOTION V4.1 and V4.2/SINAMICS V2.5 and 2.6
SINAMICS
Integrated
1. CX32 2. CX32 3. CX32 4. CX32
SERVO D435 5+1 (5 drives + 1
ALM
1)
)
6+1 6+1 --- ---
SERVO
D445/D445-1
5+1 6+1 6+1 6+1 6+1
VECTOR D435 3+1 4+1 4+1 --- ---
VECTOR
D445/D445-1
3+1 4+1 4+1 4+1 4+1
1)
ALM = Active Line Modules; Basic Line Modules (BLM), and Smart Line Modules (SLM)
can also be used.
Connection
4.5 Connecting DRIVE-CLiQ components
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 61
SIMOTION V4.0 HF2/SINAMICS V2.4
Table 4- 4 Quantity structure for SIMOTION V4.0 HF2/SINAMICS V2.4
SINAMICS
Integrated
1. CX32 2. CX32 3. CX32 4. CX32
SERVO D435 5+1 (5 drives + 1
ALM
1)
)
6+0 6+0 --- ---
SERVO D445 5+1 6+0 6+0 6+0 ---
VECTOR D435 3+1 4+0 4+0 --- ---
VECTOR D445 3+1 4+0 4+0 4+0 ---
1)
ALM = Active Line Modules; Basic Line Modules (BLM), and Smart Line Modules (SLM)
can also be used.

Note
Mixed operation of servo and vector-controlled drives
Mixed operation of servo and vector-controlled drives is not possible on a CX32. Therefore,
drives on a CX32 must be operated in servo or in vector mode only. As with the SIMOTION
D4x5, mixed operation of servo-controlled and V/f-controlled drives is possible on a CX32.
V/f-controlled drives
A maximum of eight V/f-controlled drives are supported by each CX32.

SIZER
The SIZER configuration tool makes it easy to configure the SINAMICS S120 drive family,
including SIMOTION.
It provides you with support for selecting and dimensioning the components required for a
Motion Control task.
Additional references
Further information on the CX32 can be found in the SIMOTION D4x5 Manual.
Connection
4.6 Connecting inputs/outputs
SIMOTION D4x5
62 Commissioning and Hardware Installation Manual, 11/2010
4.6 Connecting inputs/outputs
Connecting cables for the inputs and outputs of the D4x5, CX32 and TB30
The following conditions apply to connecting cables:
Use flexible cables with a cable cross-section of at least 0.25 mm
2
and maximum
0.5 mm
2

Ferrules are not required
You can use ferrules without an insulating collar in accordance with DIN 46228, Form A
long version
You can connect two cables each with a cross section of 0.25 mm
2
in one ferrule


Note
To achieve optimum interference immunity, shielded cables must be used for connecting
analog signals, measuring inputs or external zero marks.
Tools required
Screwdriver with 2 mm blade width.
Wiring inputs/outputs
1. Strip off 8 to 9 mm of cable insulation and, if necessary, press on a ferrule.
2. Wire the digital inputs of the interface for connection of the sensors.
3. Wire the digital outputs of the interface for connection of the actuators.
4. Insert the cable into the appropriate spring-loaded terminal. This is easier when you use
the screwdriver to push back the spring.
Pin assignment
For detailed information about the pin assignment of the X122/X132 interfaces of the D4x5,
refer to Section "Interfaces" in the SIMOTION D4x5 Manual. Pin assignments for the digital
inputs/outputs of the CX32 and TB30 can be found in the same manual in Section
"Supplementary system components".
Connection
4.6 Connecting inputs/outputs
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 63
4.6.1 Creating a shield connection
Using shielded cables
The following options are available for the shield connection when using shielded cables:
A shield connection using a shielding bus supplied separately
Shield connection via shield connecting element on the top of the SIMOTION D4x5
housing
Using a shielding bus
If a shielding bus is used, proceed as follows:
1. Attach the cable shield to a grounded shielding bus after the cable entry point in the
cabinet. Strip the insulation off the cable first.
2. Continue routing the shielded cable as far as the module but do not make a connection to
the shield there.
Using a shield connection on the D4x5
1. Remove the fixing bracket on the top of the D4x5.
2. Insert the cable. Please strip the insulation off the cable first.
3. Tighten the fixing bracket so that the cable shield and cable are pressed against the
device housing by the fixing bracket.
This figure shows where to attach the cables to the front panel connector and where to apply
the cable interference suppression using the shield connecting element.
Fixing bracket with
screw
Shield connection

Figure 4-6 D4x5 shield connection
Connection
4.6 Connecting inputs/outputs
SIMOTION D4x5
64 Commissioning and Hardware Installation Manual, 11/2010
4.6.2 Connecting inputs/outputs of the TB30
Pin assignment
Analog inputs/outputs
Digital inputs/outputs
Power supply for
digital outputs
TB30
X482
X481
X424

Figure 4-7 Interface arrangement on the TB30
For detailed information about the pin assignment of the X424, X481 and X482 interfaces,
refer to Section "Interfaces" in the SIMOTION D4x5 Manual.
Connection
4.6 Connecting inputs/outputs
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 65
Shield connection on the D4x5 control unit
The following figure shows the cable routing, cable connection and the connection of the
analog inputs/outputs on the TB30. The plug connector above is used accordingly for the
connection of the digital inputs/outputs.
Note:
The figure shows the
principle connection
procedure,
here showing the
example of the TB30
inserted into a CU320
Shield connection
element
on the control unit
Analog inputs/outputs
Screw
M3/0.8 Nm
X482

Figure 4-8 TB30 shield connection
The permissible bending radii for the cables must be maintained when the cables are being
laid.
Connection
4.7 Connecting PROFIBUS/MPI
SIMOTION D4x5
66 Commissioning and Hardware Installation Manual, 11/2010
4.7 Connecting PROFIBUS/MPI
4.7.1 PROFIBUS connection components
Connection components
Individual nodes are connected via bus connectors and PROFIBUS cables. Remember to
provide a bus connector with a programming port at the ends of the subnet. This will give
you the option of expanding the subnet if required, for example, for a programming device or
SIMATIC HMI device.
Use RS 485 repeaters for the connection between segments and to extend the cable.
Segments
A segment is a bus cable between two terminating resistors. A segment can contain up to 32
nodes. In addition, a segment is limited by the permissible cable length, which varies
according to the transmission rate.
Terminating resistor
A cable must be terminated with its own surge impedance to prevent line disturbances
caused by reflections. Activate the terminating resistor at the first and last node of a subnet
or segment.
Make sure that the nodes to which the terminating resistor is connected are always supplied
with voltage during power-up and operation.
Connection
4.7 Connecting PROFIBUS/MPI
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 67
4.7.2 PROFIBUS cables and connectors
Properties of PROFIBUS cables
The PROFIBUS cable is a two-core, twisted and shielded cable with defined properties:
Cable properties
Table 4- 5 Properties of PROFIBUS cables
Characteristics Values
Wave impedance Approximately 135 to 160 (f = 3 to 20 MHz)
Loop resistance 115 /km
Effective capacitance 30 nF/km
Damping 0.9 dB/100 m (f = 200 kHz)
Permissible conductor cross section 0.3 mm
2
to 0.5 mm
2

Permissible cable diameter 8 mm + 0.5 mm
Connector features
The bus connector is used to connect the PROFIBUS cable to the PROFIBUS DP interfaces
(X126, X136), thus establishing a connection to additional nodes.
Only bus connectors with a 35 cable outlet should be used in order to ensure that the front
cover can be closed.
See also
Manual SIMOTION D4x5, Chapter "Spare parts and accessories which can be ordered"
4.7.3 PROFIBUS cable lengths
Cable lengths and baud rate
The baud rate determines the cable length of a subnet segment.
Table 4- 6 Permitted cable length of a subnet segment for specific baud rates
Baud rate Max. cable length of a segment (in m)
19.6 to 187.5 kbit/s 1000
1)

500 kbit/s 400
1.5 Mbit/s 200
3 to 12 Mbit/s 100
1)
With isolated interface
Connection
4.7 Connecting PROFIBUS/MPI
SIMOTION D4x5
68 Commissioning and Hardware Installation Manual, 11/2010
Greater cable lengths
If you must realize greater cable lengths than permitted in one segment, you must use
RS 485 repeaters. The maximum possible cable lengths between two RS 485 repeaters
correspond to the cable length of a segment. You can connect up to 9 RS 485 repeaters in
series.
Note that an RS 485 repeater must be counted as a subnet node when determining the total
number of nodes to be connected. This is true even if the RS 485 repeater is not assigned its
own PROFIBUS address.
4.7.4 Rules for the laying of PROFIBUS cables
Routing bus cables
When routing the PROFIBUS cable, you must avoid:
Twisting
Stretch the bus cable
Squeezing
Boundary conditions
In addition, when routing a bus cable for indoor use, you must take into account the following
boundary conditions (dA = external cable diameter):
Table 4- 7 Boundary conditions for routing of PROFIBUS cables
Characteristics Boundary conditions
Bending radius for a single bend 80 mm (10xdA)
Bending radius for multiple bends 160 mm (20xdA)
Permissible temperature range for cable routing -5 C to +50 C
Temperature range for storage and stationary operation -30 C to +65 C
Additional references
Length codes for prefabricated cables can be found in:
Catalog PM 21; SIMOTION, SINAMICS S120, and Motors for Production Machines
Catalog IK PI (Industrial Communication)
4.7.5 Connecting PROFIBUS DP (interfaces X126 and X136)
PROFIBUS cables are connected to the corresponding interface via a bus connector.
Connection
4.7 Connecting PROFIBUS/MPI
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 69
Connecting the bus connector
Proceed as follows to connect the bus connector:
1. Plug the bus connector into the corresponding interface of the control unit.
2. Screw the bus connector into place.
If the control unit is located at the start or end of a segment, you must switch on the
terminating resistor ("ON" switch setting).
on
off
on
off
Terminating resistor
switched in
Terminating resistor
not switched in

Figure 4-9 Terminating resistor switched on and off


Note
Make sure that the nodes at which the terminating resistor is located are always supplied
with voltage during startup and operation.
Removing the bus connector
You can remove the bus connector with a looped-through bus cable from the PROFIBUS DP
interface at any time without interrupting data traffic on the bus.

WARNING
Data traffic error might occur on the bus!
A bus segment must always be terminated at both ends with the terminating resistor. This
is not the case, for example, if the last node with a bus connector is de-energized. The bus
connector draws its power from the node, and the terminating resistor is thus disabled.
Make sure that power is always supplied to nodes on which the terminating resistor is
active.

4.7.6 Connection rules in the PROFIBUS subnet
Introduction
There are a number of rules for configuring and installing cables for PROFIBUS networks to
ensure seamless communication over PROFIBUS. These rules apply to both configuring and
cabling as well as address assignment for the different network nodes.
Connection
4.7 Connecting PROFIBUS/MPI
SIMOTION D4x5
70 Commissioning and Hardware Installation Manual, 11/2010
Connection rules
Before you interconnect individual nodes in a subnet, you must assign a unique
PROFIBUS address to each node.
Narrow down the number of nodes by limiting the PROFIBUS addresses to the highest
address in the network.
Tip: Mark the address on the housing of all nodes in a subnet. Then you can always see
which address is assigned to which node in your system.
Connect all nodes in a subnet "in a series". No spur lines may be routed to the
PROFIBUS DP.
In addition, integrate the programming devices and SIMATIC HMI devices for
commissioning or servicing in the subnet in series.
If you operate more than 32 nodes on a subnet, you must use RS 485 repeaters to
connect the bus segments. More detailed information can be found in the description of
the RS 485 repeater, see the S7-300 Automation Systems, Module Data Manual.
In a PROFIBUS subnet, all segments combined must have at least one DP master and
one DP slave.
Use RS 485 repeaters to connect ungrounded bus segments and grounded bus
segments.
The maximum number of nodes per bus segment decreases with each RS 485 repeater.
That is, if a bus segment contains one RS 485 repeater, the bus segment can contain no
more than 31 additional nodes. However, the number of RS 485 repeaters does not affect
the maximum number of nodes on the bus.
Up to 10 segments can be connected in a row (max. 9 repeaters).
At least one terminator must be supplied with 5 V.
To accomplish this, the PROFIBUS DP connector with an activated terminating resistor
must be connected to a device that is switched on.
Before inserting a new node on the subnet, you must switch off its supply voltage.
The station must be inserted first and then switched on.
When a station is disconnected, the connection must first be deactivated and then the
connector withdrawn.
The bus line of a segment must be terminated at both ends. This is achieved by switching
on the terminating resistor in the PROFIBUS DP connector at the first and last node and
switching off the other terminating resistors.
Connection
4.7 Connecting PROFIBUS/MPI
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 71
Example
This illustration below shows an example configuration of a subnet with D435.

0 3
1
2 2
4
5
3
Network 2
Terminating resistor activated
DP master
DP slave
PROFlBUS DP node addresses
Max. cable length 100 m
(from terminating resistor to terminating resistor)
Network 1
12 Mbaud
A
D435
D435 RS 485
repeater
SlMOTlON S7-300
PS CPU HMl PG
SlNAMlCS S120
SlMOTlON
ET 200M
PS lM
X126
X126
X136
X136
Max. 1000 m
S
A/S
A
M
S
0 ... x
A/S
A
A A
A
S
S A/M M

Figure 4-10 Networking example for a D435
4.7.7 Operating the X136 interface as MPI
Applications
The X136 interface can also be operated as an MPI interface instead of a PROFIBUS DP
interface. The typical (default) baud rate is 187.5 Kbaud. A baud rate of up to 12 MBaud can
be set for communication with other CPUs. It should be noted, however, that a rate of
12 MBaud is not supported by all CPUs (e.g. smaller SIMATIC S7 CPUs).
The following list provides examples of when using MPI (multi-point interface) may prove
effective:
If a PC/PG is being used with an MPI interface
If an OP/TP only has an MPI interface
(newer devices have PROFIBUS or PROFINET interfaces)
If SIMOTION and SIMATIC CPUs are coupled via XSEND/XRECEIVE
Connection
4.7 Connecting PROFIBUS/MPI
SIMOTION D4x5
72 Commissioning and Hardware Installation Manual, 11/2010
When communicating with XSEND/XRECEIVE, there is no need to configure the connection
in NetPro. XSEND/XRECEIVE can be used via PROFIBUS or MPI.
Via PROFIBUS: For communication between SIMOTION devices
Via MPI: For communication between SIMOTION and SIMATIC S7 devices
The SIMOTION interface must be connected to the MPI interface of the SIMATIC S7
devices. Connection via PROFIBUS is not possible.
The baud rate of the SIMATIC S7 device must be set at the SIMOTION interface (see
documentation for the relevant SIMATIC S7 devices).
Operate MPI like PROFIBUS
The information on wiring the connector (terminating resistors) and the rules for routing of
cables for PROFIBUS apply to this interface as well. When carrying out this procedure,
consult the relevant references.
Connector features
The bus connector is used to connect the MPI bus cable to the MPI interface (X136). This
enables you to establish connections to additional nodes (e.g. PG or SIMATIC S7-CPU).
Only bus connectors with a 35 cable outlet should be used in order to ensure that the front
cover can be closed.
Additional information
See SIMOTION D4x5 Manual, Chapter "Spare parts and accessories which can be ordered"
MPI bus cable
The PROFIBUS cable specifications apply here as well;
Please note the relevant information on setting up an MPI network.
Setting up an MPI network
Keep in mind the following basic rules when setting up an MPI network:
When using the interface as an MPI interface, it is not possible to arrange additional
control for a drive in isochronous mode or to connect distributed I/Os to this interface.
An MPI bus line must be terminated at both ends. This is achieved by activating the
terminating resistor in the MPI connector in the first and last station and deactivating the
other terminating resistors.
At least one terminator must be supplied with 5 V.
This means that an MPI connector with an activated terminating resistor must be
connected to a device that is switched on.
Spur lines (cables leading from the bus segment to the station) should be as short as
possible, that is, < 5 m in length. Unused spur lines should be removed wherever
possible.
Connection
4.8 Connecting PROFINET IO components
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 73
Every MPI station must be connected to the bus first and then activated.
To disconnect the station, it must first be deactivated. Then, the station can be removed
from the bus.
Maximum cable lengths:
200 m per bus segment
2000 m total length with RS 485 repeaters

Note
You can also use intelligent DP slave functionality for PROFIBUS communication between
CPUs.

See also
PROFIBUS cables and connectors (Page 67)
PROFIBUS cable lengths (Page 67)
4.8 Connecting PROFINET IO components
4.8.1 Wiring PROFINET
Procedure
PROFINET IO is only possible on a SIMOTION D4x5 in conjunction with a CBE30
(Communication Board Ethernet). PROFINET IO components can then be connected via the
four ports of the X1400 interfaces of the CBE30. You must use suitable PROFINET cables
and connectors for this purpose.
The autocrossing functionality of the CBE30 means both crossed and uncrossed cables can
be used.
8
1

Figure 4-11 Connections on the CBE30
Connection
4.8 Connecting PROFINET IO components
SIMOTION D4x5
74 Commissioning and Hardware Installation Manual, 11/2010
Mixed operation of IRT and RT
For mixed operation of IRT and RT, note that the IRT-compatible devices must form a so-
called IRT domain, i.e., there must not be any non-IRT devices on the data transmission link
between the IRT devices.
lRT lRT RT

4.8.2 PROFINET cable
Cable and connector types

Note
For connecting PROFINET IO to CBE30 it is recommended using a connector with a 145
cable outlet (IE FC RJ45 plug 145).


Figure 4-12 RJ45 PN connector with a 145cable outlet

Connection
4.8 Connecting PROFINET IO components
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 75
Table 4- 8 Connector types for PROFINET
Connectors Designation Order No.
IE FC RJ-45 Plug 145 RJ45 FastConnect connector for
Industrial Ethernet/PROFINET with 145
cable outlet
1 package = 1 unit
1 package = 10 units



6GK1 901-1BB30-0AA0
6GK1 901-1BB30-0AB0

Table 4- 9 Cable types for PROFINET
Cable Designation Order No.
IE FC Cable GP 2 (Type A) 4-wire, shielded TP installation cable for
IE FC RJ45
6XV1 840-2AH10
IE FC Flexible Cable GP 2
(Type B)
4-wire, shielded flexible TP installation
cable for IE FC RJ45
6XV1 870-2B
IE FC Trailing Cable GP 2x2
(Type C)
4-wire TP installation cable for trailing
cable use
6XV1 870-2D
IE FC Trailing Cable 2x2
(Type C)
4-wire, shielded TP installation cable for
connection to FC OUTLET RJ45, for
trailing cable use
6XV1 840-3AH10
IE FC Marine Cable 2x2 4-wire, shielded marine-certified TP
installation cable for connection to
FC OUTLET RJ45
6XV1 840-4AH10

Table 4- 10 Stripping tool for Industrial Ethernet/PROFINET
Tools Designation Order No.
IE FC stripping tool Stripping tool for Industrial
Ethernet/PROFINET
6GK1 901-1GA00


Note
For a description of how to connect the connector to the cable, please refer to the
information on the respective connector in the Industrial Communication Catalog (IK PI
Catalog). You can also order cables and connectors there.

Connection
4.9 Routing
SIMOTION D4x5
76 Commissioning and Hardware Installation Manual, 11/2010
4.9 Routing
Routing describes the cross-network transfer of information from Network x to Network y.

4.9.1 Routing on SIMOTION D
Routing between the different interfaces
The two standard Ethernet interfaces on SIMOTION D4x5 - X120 and X130 - each form a
separate subnet; all ports on the CBE30 also form a common subnet.
Routing from subnet to subnet (IP routing) is not supported. You can use an external IP
router for this.
S7 routing from a PROFINET/Ethernet subnet to PROFIBUS is possible.
There are two options for connecting a PG/PC or HMI to a SIMOTION D with CBE30 using
S7 routing.
Connection
4.9 Routing
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 77
Engineering system / HMI to PROFINET (CBE30)

Figure 4-13 Example for PG/PC to CBE30
S7 routing to the (master) PROFIBUS interfaces (only if configured)
S7 routing to the PROFIBUS Integrated
S7 routing to the standard Ethernet interfaces ET1/ET2 (X120, X130) (as of V.4.1 SP2)
Access to the components on the same subnet (CBE30) via the switch functionality
Connection
4.9 Routing
SIMOTION D4x5
78 Commissioning and Hardware Installation Manual, 11/2010
Engineering system / HMI to PROFIBUS

Figure 4-14 Example for PG/PC to PROFIBUS
S7 routing to the other (master) PROFIBUS interfaces (only if configured)
S7 routing to the PROFIBUS Integrated
S7 routing to X1400 on the CBE30
S7 routing to the standard Ethernet interfaces (X120, X130) (as of V.4.1 SP2)
Connection
4.9 Routing
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 79
Engineering system / HMI to Ethernet

Figure 4-15 Example for PG/PC to Ethernet X120, X130
S7 routing to the other (master) PROFIBUS interfaces (only if configured)
S7 routing to the PROFIBUS Integrated
S7 routing to X1400 on the CBE30 (as of V4.1 SP2)
S7 routing between the Ethernet interfaces
4.9.2 Routing on SIMOTION D (SINAMICS integrated)
S7 routing to the internal PROFIBUS on SINAMICS Integrated
All SIMOTION D have an integrated SINAMICS drive control. In order to be able to access
drive parameters, the message frames must be routed from the external SIMOTION D
interfaces to the internal PROFIBUS DP. S7 routing can be used to access the integrated
PROFIBUS. Here, the internal PROFIBUS DP forms a separate subnet. This must be
especially taken into account for the communication to several routing nodes.
Additional references
Further information about routing and the differences between IP and S7 routing can be
found in the Communication System Manual.
Connection
4.10 Connecting Ethernet
SIMOTION D4x5
80 Commissioning and Hardware Installation Manual, 11/2010
4.10 Connecting Ethernet
4.10.1 Wiring Ethernet
Procedure
An Industrial Ethernet can be connected to the 8-pin RJ45 sockets X120 and X130.
The interfaces support a transmission rate of 10/100 Mbit/s. Suitable Ethernet cables and
connectors must be used for the Ethernet connection.
lE1/OP (X120)
lE2/NET (X130)
lndustrial Ethernet

Figure 4-16 Connecting Industrial Ethernet
4.10.2 Ethernet cables and connectors
Characteristics of the cables
A shielded twisted pair cable is used for the networking.
Connection
4.10 Connecting Ethernet
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 81
Recommended connecting cables
The following cables are available:
SIMATIC NET, Industrial Ethernet TP XP CORD RJ45/RJ45
TP cable prefabricated with 2xRJ45 connectors
Crossed send and receive cable
Order no.: 6XV1870-3R ( - length code)
SIMATIC NET, Industrial Ethernet TP CORD RJ45/RJ45
TP cable prefabricated with 2xRJ45 connectors
Uncrossed send and receive cable
Order No.: 6XV1870-3Q ( - length code)
Devices with Ethernet interfaces can have various pin assignments.
In the case of terminal devices, for example, the send line may be on pins 1 and 2, while
pins 1 and 2 on a switch or hub may connect to the receive line. If two devices are
connected using Ethernet, the type of device will dictate whether crossed or uncrossed
Ethernet cables need to be used. (For example, a crossed cable is required if two Ethernet
terminal devices are directly connected.)
You require a crossed cable for the PG/PC connection if your PG/PC does not have an
Ethernet interface with autocrossing functionality.
Additional references
For further information about the cables and connectors, see the
Industrial Communication IK PI Catalog.
Connection
4.10 Connecting Ethernet
SIMOTION D4x5
82 Commissioning and Hardware Installation Manual, 11/2010

SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 83
Commissioning (hardware) 5
5.1 Requirements for commissioning
Requirements
The following requirements must be satisfied for the initial commissioning of the SIMOTION
D4x5 and the SINAMICS S120 modules required for operation (SINAMICS S120 line
modules and SINAMICS S120 motor modules):
Your system with SIMOTION D4x5 has been installed and wired.
Your PG/PC has been connected to the SIMOTION D4x5 via a PROFIBUS or Ethernet
interface or via PROFINET (CBE30).
Commissioning steps
Commissioning the hardware involves the following steps:
1. Inserting the CF card (Page 83)
2. Checking the system (Page 85)
3. Switching on the power supply (Page 85)
Additional references
For information on installing/mounting and commissioning the SINAMICS S120 components,
refer to the SINAMICS S120 Commissioning Manual.
5.1.1 Inserting the CompactFlash card
Properties of the CF card
The CF card is mandatory for operation of the SIMOTION D4x5. The SIMOTION Kernel and
the software used to control the drives (SINAMICS firmware) are contained on the CF card.
In order to load the SIMOTION kernel, the CF card must be inserted when the SIMOTION
D4x5 is powered up.

CAUTION
The CompactFlash card may only be inserted or removed when the SIMOTION D4x5
control unit is disconnected from the power supply. SIMOTION D4x5 is in a de-energized
state when all the LEDs are OFF.

Commissioning (hardware)
5.1 Requirements for commissioning
SIMOTION D4x5
84 Commissioning and Hardware Installation Manual, 11/2010
Procedure
To insert the CF card, carry out the following steps:
1. The direction of insertion of the CF card is indicated by an arrow located on both the plug-
in slot and the CF card. Align the CF card with the arrows.
2. Gently insert the CF card into the empty plug-in slot of the SIMOTION D4x5 until it clicks
into place.
If correctly inserted, the CF card is flush with the housing.
CompactFlash
card
Arrow

Figure 5-1 Inserting the CF card
See also
Changing the CompactFlash Card (Page 295)
Commissioning (hardware)
5.1 Requirements for commissioning
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 85
5.1.2 Checking the system
Procedure
Check the final installed and wired system one more time before it is switched on, keeping in
mind the safety points in the following check list:
Have you observed all ESD measures when handling the components?
Have all screws been tightened to their specified torque?
Have all connectors been properly inserted and locked/screwed?
Are all components grounded and have all shields been attached?
Have you taken the load capacity of the central power supply into consideration?
DANGER

SIMOTION D445/D445-1 must not be operated without a fan/battery module.
SIMOTION D445/D445-1 will not power up without a fan/battery module.
5.1.3 Switching on the power supply
Switching on the external power supply
Power is supplied to the SIMOTION D4x5 via an external power supply unit such as SITOP.
Switch on this power supply.

CAUTION
It is essential to ensure that the external 24 VDC power supply to the D4x5 is not
interrupted for longer than 3 ms. After the expiration of these 3 ms, the SIMOTION D4x5
powers down and can be recommissioned with OFF/ON only.
For additional information, refer to the section titled Properties of the user memory
(Page 89).

Power-up of control unit
Once the power supply has been switched on, the SIMOTION D4x5 begins to power up:
1. At the start of the power-up, all LEDs are briefly illuminated. The LEDs on the SIMOTION
D4x5 enable you to track the progress of the power-up. Any errors are displayed.
2. Power-up of the SIMOTION Kernel
Commissioning (hardware)
5.1 Requirements for commissioning
SIMOTION D4x5
86 Commissioning and Hardware Installation Manual, 11/2010
3. All DRIVE-CLiQ connections (e.g. with the SINAMICS S120 Active Line Module) are also
detected automatically.


Note
As long as the RDY LED continues to flicker, power-up is not complete and it is not
possible to go online.
During commissioning the components' firmware is upgraded or downgraded
automatically based on the FW version on the CompactFlash Card and the FW version
on the SINAMICS components (DRIVE-CLiQ components, CBE30, PM340, etc.).
The update can take several minutes and its progress is tracked by corresponding
messages appearing in the alarm window of SIMOTION SCOUT.
SIMOTION D4x5/CX32/DRIVE-CLiQ components:
An FW update on DRIVE-CLiQ components is indicated by the RDY LED flashing
red/green:
FW update running: RDY LED flashing slowly (0.5 Hz)
FW update complete: RDY LED flashing quickly (2 Hz)
These flashing patterns are also displayed on the yellow RDY LED on the
SIMOTION D/CX32, and indicate that a FW update has been carried out on components
connected to the SIMOTION D/CX32 or that all components have completed the FW
update.
Go offline once all the FW updates are complete, POWER ON the upgraded/downgraded
components.
CBE30 Option Board:
During the firmware update, the OPT LED of the SIMOTION D module and the SYNC
LED of the CBE30 flash green.
4. The first time it is energized, the SIMOTION D4x5 goes to STOP mode following power-
up.
Following power-up, the SIMOTION D4x5 is in a state in which it can be configured.
Fan/battery module on a SIMOTION D445/D445-1 faulty or missing
While the SIMOTION D445/D445-1 is powering up, a test is performed to check whether the
fan/battery module is functioning properly. If a fan/battery module is not mounted or is
mounted improperly, the kernel is not downloaded and the RDY LED flashes red/yellow (2
Hz). Switch off the power supply and correct the fault before switching on the power supply
again.

DANGER
If the SIMOTION D445 runs for more than a minute with a missing or faulty fan/battery
module, the module will switch to the reset state after approximately 1 minute. This state
can only be reset with a switch-off.

Commissioning (hardware)
5.2 RESET button
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 87
DANGER
If the SIMOTION D445-1 needs to be cooled (fan switches on with temperature control) and
this is not possible due to a fan/battery module having been removed or being faulty, the
module state will change to reset after approximately 1 minute. This state can only be reset
with a switch-off.

5.2 RESET button
Layout
The RESET button is located behind the blanking cover on the SIMOTION D4x5.
Performing a reset
A reset causes the entire system to be reset and forces the system to power up again. This
operation is comparable with a "Power on Reset" but does not require the disconnection of
the 24 V power supply.
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5.3 User memory concept
SIMOTION D4x5
88 Commissioning and Hardware Installation Manual, 11/2010
5.3 User memory concept
5.3.1 SIMOTION D4x5 memory model
The following figure provides an overview of the memory model of SIMOTION D4x5.
Programming device
"SlMOTlON SCOUT" ES
CF card
TPs
User data
lP parameters,
DP parameters
SlMOTlON Kernel
SlMOTlOND4x5
Non-retentive data
TPs
User data
SlMOTlON Kernel
Retentive data
Diagnostics buffer
Retentive user area
(retain variable)
lP parameters,
DP parameters
RAM to ROM
D4x5 ramp-up
D4x5 ramp-up
D4x5 ramp-up
Absolute encoder
offset
Download

Figure 5-2 SIMOTION D4x5 memory model

As a result, the SIMOTION Kernel (D4x5 firmware) contains the functions needed for
virtually all applications and corresponds in essence to a PLC with the IEC 61131-3
command set plus system functions for controlling various components, such as inputs and
outputs.
The SIMOTION Kernel can be expanded by loading technology packages (TPs), e.g. for
motion control or temperature control.
In the following chapters, you will learn information about the user memories and the steps
involved in certain operations.
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Commissioning and Hardware Installation Manual, 11/2010 89
5.3.2 Properties of the user memory
Non-volatile data
Non-volatile data make it possible to retain relevant data for the user and the system even
when the SIMOTION D4x5 has been switched off. You will find information about the area
that can be used for non-volatile data in the SIMOTION SCOUT Configuration Manual and in
the SIMOTION D4x5 Technical Data Manual.
A SIMOTION device has the following non-volatile data:
Table 5- 1 Non-volatile data contents
Non-volatile data Content
Kernel data
Last operating mode
IP parameters (IP address, subnet mask, router address)
DP parameters (PROFIBUS DP address, baud rate)
Diagnostics buffer
Retain variables
Variables in the interface or implementation section of a unit declared
with VAR_GLOBAL RETAIN
Global device variables set with the "RETAIN" attribute
Retain TO Absolute encoder offset
DCC blocks SAV blocks and user-defined blocks with retain behavior ("SAV = SAVE",
blocks for the non-volatile data backup)


Note
DCC SIMOTION blocks with retain behavior act like retain variables in terms of copying RAM
to ROM, resetting memory, downloading, backing up non-volatile data
(_savePersistentMemoryData) and backing up data.
With SINAMICS Integrated the SINAMICS retain data is buffered (this is also the case with
SINAMICS DCC, where SuperCap or a battery is used). With _savePersistentMemoryData
data is not saved.
With CX32 there is permanent data buffering via the FRAM.
With_savePersistentMemoryData data is not saved.
For further information on DCC, see the "DCC Programming" Programming Manual.

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90 Commissioning and Hardware Installation Manual, 11/2010
The non-volatile data of the SIMOTION D4x5 has the following properties:
Table 5- 2 Non-volatile data properties
Property Meaning
City: The non-volatile data is in the SIMOTION D SRAM. The following backup
options are available:
SRAM backed up by SuperCap (maintenance-free), or
SRAM backed up by fan/battery module; with battery mounted
Non-volatile data backed up from SRAM to CF card
(_savePersistentMemoryData)
Backup time:
SuperCap: 5 days, minimum
Battery: At least 3 years

The integral real-time clock in the SIMOTION D4x5 is also backed up, like the SRAM. The
same backup time applies for the integral real-time clock.
If the buffer time is exceeded on the real-time clock, the time is reset.
Fan/battery module
If the backup time is insufficient, a battery can be connected by means of an external
fan/battery module. The backup time of a used type of battery is at least 3 years.
A 3 V lithium SN: 575332 battery type (with cable tail and connector) is used. The battery
can be replaced without data loss, because the retain data is backed up internally via the
SuperCap.
The fan/battery module is optional for the D425/D435 and must be ordered separately. Since
the fan/battery module is always required for the D445/D445-1 it is included in the scope of
delivery of a D445/D445-1 (see the SIMOTION D4x5 Manual)
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Commissioning and Hardware Installation Manual, 11/2010 91
CF card
With the _savePersistentMemoryData system function, the user program can back up the
contents of the non-volatile data to the CF card. This ensures that the retain variables and
the absolute encoder position are backed up in the event that a spare part is used.

Note
IP and DP parameters in the non-volatile data
If the CF card contains a configuration, the IP and DP parameters are loaded from the CF
card during power-up and used by the SIMOTION device. The SIMOTION D4x5 uses the
addresses defined in these parameters to go online. During power-up, the IP and DP
parameters on the CF card are also written to the non-volatile data. If the SIMOTION device
is then powered up with a CF card with no configuration, the IP and DP parameters are
retained in the non-volatile data and are used by the device. Thus, the SIMOTION device
can continue to go online if a configuration was loaded with SIMOTION SCOUT at least once
or if the SIMOTION device is powered up with a CF card containing a configuration.

Volatile data (RAM / current data RAM)
The volatile data is defined by the following properties:
The volatile data is located in the RAM memory of the SIMOTION device.
The download data of SIMOTION SCOUT are written to this memory.
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92 Commissioning and Hardware Installation Manual, 11/2010
This data is lost with the SIMOTION D4x5 is switched off.
The "volatile data" area contains the following data:
SIMOTION Kernel (D4x5 firmware)
Technology packages (TP)
User data (programs, configuration data, parameter settings)
Target
device
Commissioning
ROM
RAM
Current RAM
Micro Memory Card
CompactFlash Card
Memory Card
(working memory)
Next
RAM to
ROM
copy
Copy actual data
to RAM
(no system
variables)
TO restart
or immediately
Config data in
RUN
System
variables
Download
Upload
(load memory)

Figure 5-3 Configuration data and system variables in the volatile memory
Further information about memory management for SIMOTION appears in the SIMOTION
SCOUT Basic Functions Function Manual.
CompactFlash card (CF card)
The CF card contain the following data:
SIMOTION Kernel (D4x5 firmware)
Technology packages (TP)
User data (units, configuration data, parameter settings, task configuration)
IP parameters (IP address, subnet mask, router address)
DP parameters (PROFIBUS DP address, baud rate)
Also, if required:
User data saved with _savePersistentMemoryData and _export/_saveUnitDataSet
Data from SIMOTION IT
Archived SCOUT project
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Commissioning and Hardware Installation Manual, 11/2010 93
5.3.3 Operations and their effect on the user memory
The operations marked with arrows in the figures entitled "SIMOTION D4x5 memory model"
and "Configuration data and system variables in the volatile memory" and their effects on the
user memory will be described below.
SIMOTION SCOUT Download
The "Download" menu command transfers the following data from the engineering system to
the "volatile data" area:
User data (units, configuration data, parameter settings, task configuration)
Technology packages (TPs)
In addition, the IP and DP parameters are saved to the "non-volatile data" area. The retain
variables are set to their initial values, but this depends on the settings in SIMOTION
SCOUT. If the SIMOTION D4x5 is switched off following the download, the volatile data is
lost.
Copy RAM to ROM
The Copy RAM to ROM menu command saves the following data via the engineering
system to the CF card:
Technology packages and user data (units, configuration data, parameters, task
configuration) of the "volatile data" area
Current data values are copied to the "volatile data" area, depending on the settings in
SIMOTION SCOUT.


Note
The "Copy RAM to ROM" menu command does not save the current values of the retain
variables to the CF card. Use the system function "_savePersistentMemoryData" for this.
Current RAM
If you change the system variable values, these take immediate effect in the current RAM.
New configuration data values are initially stored in the Next memory. Configuration data that
takes immediate effect is automatically transferred to the current RAM. Configuration data
that will only become active following a RESTART on the technology object (set the
restartactivation system variable to the ACTIVATE_RESTART value) is not written to the
current RAM until after the RESTART.
To save the configuration data changed online to the offline project, you must first transfer
the content of the current RAM to the RAM using the menu command "Target system" >
"Copy current data to RAM".
Once you have done this, the configuration in SCOUT will no longer be consistent with the
configuration in the target device, as a consistency check is performed on the RAM data.
Read the data from the RAM using the menu command "Target system" > "Load" > "Load
CPU / drive unit to PG" (for the configuration data only) to re-establish a consistent system
state.
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94 Commissioning and Hardware Installation Manual, 11/2010
To save the configuration to the CF card in non-volatile format, use the menu command
"Target system" > "Copy RAM to ROM".
Via the menu "Options" > "Settings..." > "Download", you can set whether current values are
to be copied to the RAM and configuration data loaded to the PG with "Copy RAM to ROM"
using the option "Transfer current values with copy RAM to ROM".

Note
The "Copy current data to RAM" command does not transfer the values of the system
variables to the RAM memory. This means that "Save to memory card (Copy RAM to ROM)"
or "Save in the engineering project (Load CPU / drive unit to PG)" is not possible.
In order to ensure that system variable values can also be saved to the engineering project
and memory card, the system variable values must be changed OFFLINE and then
downloaded to the target device and saved.

SIMOTION D4x5 power-up
During power-up of the SIMOTION D4x5, the SIMOTION Kernel is loaded from the CF card
to the "volatile data" area.
When the SIMOTION D4x5 is switched off, the contents of the "volatile data" area are lost.
When the SIMOTION D4x5 is powered up again, the following data is loaded from the CF
card:
Technology packages and user data in the "volatile data" area
IP and DP parameters in the "non-volatile data" area
Backing up non-volatile data
You have the following options for backing up non-volatile data on the CF card:
In the user program:
With the "_savePersistentMemoryData" system function, the user program can back up
the non-volatile data content to the CF card. This ensures that the retain variables and
the absolute encoder position are backed up in the event that a spare part is used.
Using a switch position (SIMOTION D4x5 Service selector switch) or IT DIAG. See
Section Diagnostic data and non-volatile data (Page 310).
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Commissioning and Hardware Installation Manual, 11/2010 95
The contents are saved to the "PMEMORY.XML" backup file in the "USER/SIMOTION"
directory. On the system side, this system function ensures that a consistent overall image of
the non-volatile data is always available the next time the unit is powered on, even if there is
a power failure during backup. To this end, before a new backup file is created, any existing
backup file is renamed as "PMEMORY.BAK". If the save operation to the new backup file
fails (e.g. because the capacity of the CF card is insufficient), this backup copy of the backup
file is used the next time an attempt is made to restore the non-volatile data content. If the
new file is successfully created, the backup copy of the backup file is deleted.

NOTICE
Non-volatile data that is not backed up to the CF card will be lost if a spare part is installed
(in the event of a module defect). For example, failing to back up the current values of the
retain variables will result in them being lost and reset to their initial values.
If an absolute encoder overflow occurs after "_savePersistentMemoryData", the actual
position value will no longer be correct once the non-volatile data has been restored. In this
case, homing (absolute encoder adjustment) must be repeated.

With the SCOUT functions "Back up variables" and "Restore variables", you also have the
option of backing up to your PC and restoring data that was changed during operation and
only stored in the runtime system.
Reloading non-volatile data
Data backed up on the CF card with _savePersistentMemoryData is reloaded in the following
scenarios:
1. Loss of the SRAM contents (buffer failure due to empty SuperCap or empty backup
battery)
2. After a module replacement, see Section Replacing modules (spare parts) (Page 267)
3. After a memory reset, see Section SIMOTION D4x5 memory reset (Page 249)
4. Via switch position, see Section Deleting/restoring non-volatile data (Page 317)
Power failure
In the event of a power failure, the data in the SRAM of the control unit is backed up by an
internal SuperCap and a fan/battery module (where applicable).
The non-volatile data is available again the next time the unit is powered up. Thus, the
control unit is immediately operational without data loss.

Note
After power off and then on again, the SIMOTION part starts in coordination with the
SINAMICS Integrated, whereby the SINAMICS Integrated takes longer to power up. The
"Incoming station" alarm is triggered, and the PeripheralFaultTask is called.

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96 Commissioning and Hardware Installation Manual, 11/2010
Power-up and non-volatile data
The table below lists the cases that can arise during power-up in conjunction with the non-
volatile data and explains how they are handled.
Table 5- 3 Cases: Power-up with non-volatile data
Case Initial condition Result
1 The non-volatile data is valid. SIMOTION D4x5 powers up with the non-volatile data,
meaning, for example, that the PROFIBUS address in
the non-volatile data is valid.
2 The non-volatile data is invalid and there is no backup file
(PMEMORY.XML) and no backup copy of the backup file
(PMEMORY.BAK).
SIMOTION D4x5 copies the default settings to the non-
volatile data and powers up with this data. In this case,
for example, the default PROFIBUS address is used.
3 The non-volatile data is invalid. A valid backup file
(PMEMORY.XML) exists.
SIMOTION D4x5 copies the backup file contents to the
non-volatile data and powers up with this data.
4 The non-volatile data is invalid, the backup file is invalid
and there is no backup copy of the backup file
(PMEMORY.BAK).
SIMOTION D4x5 copies the default settings to the non-
volatile data and powers up with this data, in which
case, for example, the default PROFIBUS address is
used.
5 The non-volatile data is invalid; a backup file exists, but it
is invalid; a backup copy of the backup file exists and is
valid.
SIMOTION D4x5 copies the backup file contents to the
non-volatile data and powers up with this data.
Non-volatile data diagnostics
The user can determine the status of the non-volatile data and the battery using the
diagnostic buffer, system variables, and PeripheralFaultTask.
Evaluating via the diagnostics buffer
When they are issued, the following messages are entered once in the diagnostics buffer:
Table 5- 4 Messages of the diagnostics buffer
Entry Meaning Remedy
Level 1 battery voltage warning
1)
Battery voltage below prewarning level Replace battery in the
fan/battery module
Level 2 battery voltage warning
1)
The battery voltage is below the warning
level, backing up of non-volatile data /
clock can no longer be guaranteed.
Replace battery in the
fan/battery module
Battery voltage for data backup in
permissible range

Non-volatile data memory voltage error The buffer voltage of the SuperCap or
the battery was too low after Power On.
Possible data loss in the non-volatile
data / clock.
Replace battery in the
fan/battery module or charge the
SuperCap over a longer period.
Non-volatile data loaded from a file
(Persistent Data File Loading done)
Non-volatile data has been successfully
restored from the backup file on the CF
card.
-
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Entry Meaning Remedy
Non-volatile data loaded from the backup file
(Persistent Data Backup File Loading done)
Non-volatile data has been successfully
restored from the backup copy of the
backup file on the CF card.
-
Error while loading non-volatile data from a
file
(Persistent Data File Loading Failure)
Backup file or backup copy of backup
file could not be loaded.
Possible causes:
Backup file or backup copy of
backup file does not exist
Data in backup file is invalid
Use the
"_savePersistentMemoryData"
system function to generate a
valid backup file.
Device with battery module Fan/battery module is present. -
Device without battery module Fan/battery module is not present. Connect fan/battery module if
necessary.
1)
These warnings are only signaled when the fan/battery module has been inserted.
Refer to the SIMOTION SCOUT Configuration Manual for information about how to read out
the contents of the diagnostic buffer.
Evaluating via PeripheralFaultTask
Battery status changes in RUN are reported to the user program by calling
PeripheralFaultTask. Changes can be evaluated here using Taskstartinfo:
TSI#InterruptId = _SC_PC_INTERNAL_FAILURE (= 205)
TSI#details = 16#00000040 .
If there is no fan/battery module present or no battery inserted when the power is on, or in
STOP mode, no PeripheralFaultTask will be triggered when powering up or in RUN
(application case: D4x5 should generally be operated without a fan/battery module or
battery).
References
Detailed information on setting up TaskStartInfo(#TSI) can be found in the SIMOTION
SCOUT Basic Functions Function Manual.
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Evaluating via system variables
The system variables in the "device.persistentDataPowerMonitoring" structure indicate the
status of the non-volatile data and the battery.
Table 5- 5 Status of the non-volatile data and battery
System variable Designation State Updating
powerFailure Buffer voltage
(SuperCap or battery)
too low, possible loss of
data
NO (91)
YES (173)
"YES" was set at too
low a buffer voltage
when powering up;
status needs to be
reset to "NO" via the
application.
persistentDataState Reading the persistent
data
See the table below,
"State of non-volatile
data following power-
up".
During power-up
warningBatteryVoltage
Level1
1)

Battery voltage below
the prewarning level
NO (91)
YES (173)
During a status change,
remains set if Level 2 is
reached
warningBatteryVoltage
Level2
1)

Battery voltage below
the warning level
NO (91)
YES (173)
During a status change
1)
Bothbattery warning levels are set under the following conditions:
The fan/battery module has been installed and the battery has been inserted but the
battery voltage is below warning level 2.
The fan/battery module has been installed but no battery has been inserted (as of V4.1
SP2).
No fan/battery module has been installed (as of V4.1 SP2).
System variable "device.persistentDataPowerMonitoring.persistentDataState" indicates the
state of the non-volatile data after power-up.
Table 5- 6 State of non-volatile data after powering up (persistentDataState system variable)
State Meaning
FROM_RAM (1) Non-volatile data in the SIMOTION device is used
FROM_FILE (2) Non-volatile data is restored from the backup file
FROM_BACKUP (3) Non-volatile data is restored from the backup copy of the backup file
INVALID (4) Data in the non-volatile data and in the backup file / backup copy of backup
file is invalid or non-existent/deleted.
The SIMOTION device has copied the default settings to the non-volatile
data and used this data to power up.
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Requirement/availability of the battery (as of V4.2)
System variables can be used to evaluate:
Whether a battery is required for the operation of the device (or not)
Whether a battery is available (or not)
Table 5- 7 System variable batterynecessary/batteryexisting
System variable
on the device
States Description
fanbattery of the structfanbattery type (the system variables are of the enumfanbattery type)
MANDATORY Battery is required for the backup of the retain data and
the real-time clock (RTC) of the device. .batteryexisting
can be used to query whether a battery is available.
OPTIONAL The retain data and the real-time clock (RTC) are backed
up via SuperCap. A battery can be used as an option to
extend the backup time. .batteryexisting can be used to
query whether a battery is available.
Example: D4x5
OPTIONAL_RTC
1)
A battery is not required for the backup of the retain data.
Only the real-time clock (RTC) is backed up via
SuperCap. A battery can be used as an option to extend
the backup time of the real-time clock. .batteryexisting
can be used to query whether a battery is available.
Example: D4x5-2
.batterynecessary
NOT_MANDATORY
1)

A battery is not required for the backup of the retain data.
The real-time clock (RTC) is backed up via SuperCap.
Example: D410
EXISTING EXISTING is only displayed when .batterynecessary is
set to:
MANDATORY or
OPTIONAL or
OPTIONAL_RTC
and a battery is available.
.batteryexisting
NOT_EXISTING Battery is not available.
1)
If the SuperCap is discharged, the contents of the real-time clock (RTC) are lost
Commissioning (hardware)
5.4 Fan
SIMOTION D4x5
100 Commissioning and Hardware Installation Manual, 11/2010
5.4 Fan
5.4.1 Cooling the SIMOTION D4x5
Overview
If natural convection proves inadequate in terms of dissipating heat away from the module,
and the supply air temperature exceeds the permissible limits as a result, in the case of
SIMOTION D425/D435 an external fan/battery module must be mounted on the underside of
the module. A fan/battery module is always required for SIMOTION D445/D445-1.
Table 5- 8 Fan/battery module for SIMOTION D4x5
Property SIMOTION
D425
SIMOTION D435 SIMOTION D445 SIMOTION D445-1
D435 with order no.
6AU1 435-0AA00-
0AA1: Optional
Fan/battery
module
Optional
D435 with order no.
6AU1 435-0AA00-
0AA0: Required for
supply air
temperatures of 43
C and above
Always required

Always required
Fan/battery
module
included in the
scope of
delivery of the
D4x5
- - - - Fan/
battery module
(single fan) with
order no.
6FC5 348-0AA01-
0AA0
Double fan/
battery module
with order no.
6FC5 348-0AA02-
0AA0
Fan/battery
modules which
can be used in
principle
Type
6FC5 348-
0AA01-0AA0
only (single
fan)
Type
6FC5 348-0AA01-
0AA0 only (single
fan)
Type
6FC5 348-0AA01-
0AA0 only (single
fan)
Type 6FC5 348-
0AA01-0AA0 (single
fan) and Type
6FC5 348-0AA02-
0AA0 (double fan)
Max.
permissible
supply air
temperature
55 C 55 C 55 C 55 C
Fan control Switches on
at supply air
temperatures
of approx. 43
C and above
Switches on at
supply air
temperatures of
approx. 43 C or
above
Fan is always on The fan switches on
with temperature
control (continuous
operation at approx.
40 C and above)
The fan/battery modules are usually supplied with a backup battery.
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5.4 Fan
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Fan faults
Fan faults are indicated as follows:
Entry in diagnostic buffer
In the event of a fan failure the RDY LED flashes red/yellow at 2 Hz (SIMOTION
D445/D445-1 only), which means:
With a fan/battery module, the single fan has failed
With a double fan/battery module, both fans have failed
Indicated via system variable
Call to the PeripheralFaultTask
For further information on the evaluation of fan faults, see Section
Overview of the fan/battery module states (Page 103).
5.4.2 Fan/battery module on the D425/D435
SIMOTION D425/D435 can be operated without a fan/battery module. It is for this reason
that the standard scope of delivery of the D425/D435 does not include a fan/battery module.
In the absence of a fan/battery module when the line supply is connected, a warning will be
output by setting variable device.CpuDataRW.fanwarning = "NO".
If there is no fan/battery module present when the power is on, or in STOP mode, no
PeripheralFaultTask will be triggered when powering up or in RUN (application case:
D425/D435 is generally to be operated without a fan/battery module).
5.4.3 Fan/battery module on the D445/D445-1
A fan/battery module is always required for operation of SIMOTION D445/445-1. A
corresponding module including backup battery is, therefore, included in the scope of
delivery of the D445/D445-1 control unit.
SIMOTION D445: Scope of delivery including fan/battery module (single fan)
SIMOTION D445-1: Scope of delivery including double fan/battery module
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SIMOTION D445
A fan/battery module (single fan) is always used with SIMOTION D445.
While the SIMOTION D445 is powering up, a test is performed to check whether the
fan/battery module is functioning properly. If the fan/battery module is missing or faulty, the
kernel is not downloaded and the RDY LED flashes red/yellow (2 Hz). Switch off the power
supply and eliminate the fault. Then switch the power supply back on.

Note
If the SIMOTION D445 runs for more than a minute with a missing or faulty fan/battery
module, the module will switch to the RESET state after approximately 1 minute (7-segment
display shows "8"). This state can only be reset with a switch-off.

SIMOTION D445-1
For increased availability a double fan/battery module is used as standard on SIMOTION
D445-1.
The double fan/battery module guarantees sufficient cooling even if just one fan is
operational.
If one of the fans fails, the remaining fan continues under full load. The fan failure is signaled
by the generation of an event in the PeripheralFaultTask. In this case it is strongly
recommended that the double fan/battery module is replaced at the next available
opportunity.
Checks are performed during power-up to determine whether the double fan/battery module
on SIMOTION D445-1 is functioning correctly (i.e. at least one of the two fans is working). If
a double fan/battery module is missing or faulty, the kernel is not downloaded and the RDY
LED flashes red/yellow (2 Hz). Switch off the power supply and eliminate the fault. Then
switch the power supply back on.

Note
If the SIMOTION D445-1 needs to be cooled (fan switches on with temperature control) and
this is not possible due to a fan/battery module having been removed or being faulty, the
module state will change to the RESET state after approximately 1 minute (7-segment
display shows "8"). This state can only be reset with a switch-off.
If only one fan in the double fan/battery module fails, the module is still regarded as
functional, although it should be replaced as soon as possible. If neither of the fans is
working, the double fan/battery module is identified as defective.

Commissioning (hardware)
5.4 Fan
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 103
5.4.4 Overview of states, fan/battery module
The states that can occur during operation are described in the following.
Table 5- 9 Overview of states
System variables
3)
State Fan
4)
PeripheralFaultTask

Diagnostic buffer entry
_cpuDataRW.
fanWarning
_cpuDataRW.
redundantfanWar
ning
2)
(as of
V4.2)
Single fan PeripheralFaultTask:
Is not called
Diagnostic buffer entry:
Fan on the module is defective
= YES
1)
= NO Failure of one
fan during
STOP, then
RUN
Double fan PeripheralFaultTask:
Is not called
Diagnostic buffer entry:
Redundant fan on the module is defective
= NO = YES
Failure of both
fans during
STOP, then
RUN
Double fan PeripheralFaultTask:
Is not called
Diagnostic buffer entry:
Fan on the module is defective
= YES
1)
= NO
Single fan PeripheralFaultTask:
TSI#InterruptId =
_SC_PC_INTERNAL_FAILURE (= 205)
TSI#details = 16#00000080

Diagnostic buffer entry:
Fan on the module is defective
= YES
1)
= NO Failure of one
fan during
RUN
Double fan PeripheralFaultTask:
TSI#InterruptId =
_SC_PC_INTERNAL_FAILURE (= 205)
TSI#details = 16#00004000

Diagnostic buffer entry:
Redundant fan on the module is defective
= NO = YES
Failure of both
fans during
RUN
Double fan PeripheralFaultTask:
TSI#InterruptId =
_SC_PC_INTERNAL_FAILURE (= 205)
TSI#details = 16#00000080

Diagnostic buffer entry:
Fan on the module is defective
= YES
1)
= NO
1)
For D445/D445-1: Module goes into the RESET state after approx. 1 minute.
2)
Maintenance: Replace double fan/battery module at the next available opportunity.
3)
The "YES" value must be reset to "NO" by the application.
4)
Single fans are only supported by SIMOTION D4x5.
Fan faults are detected if through
Commissioning (hardware)
5.4 Fan
SIMOTION D4x5
104 Commissioning and Hardware Installation Manual, 11/2010
A cyclic fan test (as of V4.2)
Or when the fan is switched on
a malfunction is detected (fan does not turn or fan turns at too low a speed).

Note
If the "redundant fan" is already defective in a double fan/battery module when the system is
powered-up, this is detected as a single fan/battery module depending on the type of defect
(e.g. a wire breakage).
You should, therefore, also set the .fanexisting system variable to the "SINGLE" state to alert
the personnel operating the machine to the fact that no is redundancy available.

Diagnostics buffer entry
The diagnostics buffer entries have the following meanings:
Fan on the module is defective
All of the fans in a fan/battery module have failed
There is no redundant fan available
This message only occurs in the case of modules that support double fan/battery
modules with a redundant fan.
The message occurs:
If it is only the redundant fan that has failed on a double fan/battery module or
If a single fan/battery module is connected, but the module also supports a double
fan/battery module in principle (with V4.2, this is only the case for D445-1)
Requirement/availability of a fan (as of V4.2)
System variables can be used to evaluate:
Whether a fan is required for the operation of the device (or not)
Whether a fan is available (or not)
Commissioning (hardware)
5.4 Fan
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 105
Table 5- 10 System variable fannecessary/fanexisting
System variable on the
device
States Description
fanbattery of the structfanbattery type (the system variables are of the enumfanbattery type)
MANDATORY Fan is required for operation of the device.
.fanexisting can be used to query whether
a fan is available.
Examples: D410, D445, D445-1,
D445-2 DP/PN, D455-2 DP/PN
OPTIONAL Fan can be used optionally. .fanexisting
can be used to query whether a fan is
available.
Examples: D425, D435
.fannecessary
NOT_MANDATORY Fan is not required for operation of the
device.
SINGLE Single fan is available.
Examples: D410, D4x5
REDUNDANT Double fan is available.
Examples: D445-1, D445-2 DP/PN,
D455-2 DP/PN
.fanexisting
NOT_EXISTING No fan available.
Example: D425 without optional fan
References
Detailed information on setting up TaskStartInfo(#TSI) can be found in the
function manual titled SIMOTION SCOUT Basic Functions.
5.4.5 Response to overtemperature
Operation at overtemperature reduces the module service life and can result in damage to
the module.
Causes
Causes of problems in the heat dissipation of the module can be, for example:
Violation of the maximum permissible air intake temperature
Free convection is not ensured (clearances are not maintained, pollution, convection is
prevented by cables)
Impermissible mounting position of the module
Commissioning (hardware)
5.4 Fan
SIMOTION D4x5
106 Commissioning and Hardware Installation Manual, 11/2010
Temperature thresholds
The internal module temperature is monitored via two module-specific temperature
thresholds:
Overtemperature is signaled when the first (lower) temperature threshold is exceeded.
When the temperature falls below the first temperature threshold again (minus a
hysteresis of approx. 5 C), "Normal temperature" is signaled.
When the second (higher) temperature threshold is exceeded, the module shuts down in
order to protect itself.
Response to overtemperature
Table 5- 11 Response of the temperature monitoring (as of V4.2)
Temperature... Response
... exceeds the 1st temperature
threshold (overtemperature)
Call of the PeripheralFaultTask:
TSI#InterruptId = _SC_PC_INTERNAL_FAILURE (= 205)
TSI#details = 16#00000002
Diagnostics buffer entry:
"Temperature exceeded in the housing"
... falls below the 1st
temperature threshold minus a
hysteresis of approx. 5 C
Call of the PeripheralFaultTask:
TSI#InterruptId = _SC_PC_INTERNAL_FAILURE (= 205)
TSI#details = 16#00000004
Diagnostics buffer entry:
"Temperature in the housing has returned to normal"
... exceeds the 2nd temperature
threshold
D445, D445-1:
Module goes into permanent RESET to protect itself (7-segment
display shows "8", RDY LED flashes red/yellow at 2 Hz).
D425, D435:
Module goes into the FAULT state to protect itself (7-segment
display shows "F", all LEDs flicker red)
References
Detailed information on setting up TaskStartInfo(#TSI) can be found in the SIMOTION
SCOUT Basic Functions Function Manual.


SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 107
Parameter assignment / addressing 6
6.1 Software requirements
SIMOTION SCOUT Engineering System
To commission the SIMOTION D4x5, the SIMOTION SCOUT Engineering System must be
installed on your PG/PC. Please read the information on the current DVD for "SIMOTION
SCOUT."
For information on how to install SIMOTION SCOUT on your PG/PC, see the
SIMOTION SCOUT Configuration Manual.

6.2 Creating a project and configuring communication
6.2.1 Creating a SIMOTION project and inserting a D4x5
Procedure
Proceed as follows to create a new project in SIMOTION SCOUT and insert a
SIMOTION D4x5:
1. Select the Project > New... menu command.
2. In the "New Project" dialog box, assign a name and confirm with "OK."
A new folder with the name of the project will be created in the project navigator.
Parameter assignment / addressing
6.2 Creating a project and configuring communication
SIMOTION D4x5
108 Commissioning and Hardware Installation Manual, 11/2010
3. In the project navigator, double-click "Insert SIMOTION device". The "Insert SIMOTION
Device" dialog box is opened:

Figure 6-1 Inserting a SIMOTION device
4. In the "Insert SIMOTION Device" dialog box, select the device, the device version and the
SIMOTION version.
5. If required, make further settings:
SINAMICS: Select either a "SINAMICS S120 Integrated" or a
"SINAMICS SM150 Integrated" (only for D445/D445-1/D455-2)
SINAMICS version: Select the SINAMICS Integrated version if several drive versions
are available for a SIMOTION version
Option module: Select a CBE30 (only for D425, D435, D445 and D445-1)
6. The Open HW Config option can be used to select whether HW Config should be opened
in the next step (e.g. in order to insert a CX32 controller extension).
7. Confirm the "Insert SIMOTION device" dialog box with "OK"
Parameter assignment / addressing
6.2 Creating a project and configuring communication
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 109
PROFINET version
With SCOUT V4.2
PROFINET version V2.1 is created for SIMOTION V4.0 devices
PROFINET version V2.2 is created for SIMOTION V4.1 and V4.2 devices
There is no selection option in the "Insert SIMOTION Device" dialog box - in exceptional
circumstances (e.g. for existing systems), PROFINET version V2.1 can still be configured for
V4.1 CPUs. A CPU replacement must be made in HW Config for this.
Please note that separate SIMOTION D firmware is available for PROFINET versions V2.1
and V2.2. The required firmware can be found on the SCOUT DVD, as well as at Internet
address (http://support.automation.siemens.com/WW/view/en/31045047)
Mixed operation of the PROFINET V2.1 and V2.2 synchronization processes is not possible
in a network.
SINAMICS Integrated type
The following selection options are available for SIMOTION D445/D445-1/D455-2:
SINAMICS S120 Integrated
SINAMICS SM150 Integrated for applications with medium-voltage converters
A separate SIMOTION D firmware is available for each of the two versions.
Version of the SINAMICS Integrated
Depending on the selected SIMOTION version, several versions are available for the
SINAMICS Integrated. Please note that a separate SIMOTION D firmware is available for
each version of the SINAMICS Integrated.
Additional references
For further information on IRT in accordance with PROFINET standard IEC 61158 V2.1 and
V2.2, refer to the SIMOTION Communication System Manual.
Result
If you have not yet configured a PG/PC in your project, you can select the interface for the
PG/PC connection now.

Parameter assignment / addressing
6.2 Creating a project and configuring communication
SIMOTION D4x5
110 Commissioning and Hardware Installation Manual, 11/2010
6.2.2 Configuring the PROFIBUS PG/PC interface
Requirements
The following requirements must be satisfied in order to configure the PG/PC interface:
You have acknowledged the "Insert SIMOTION device" dialog with "OK".
A PG/PC has not yet been configured in the project.
If these requirements have been satisfied, you can configure the interface for the PG/PC
connection in the
"Interface Selection - D4x5" dialog.
Proceed as follows to configure the PROFIBUS DP interface:
Procedure
1. In the "Select Interface - D4x5" dialog box, select "PROFIBUS DP2/MPI".

Figure 6-2 Selecting a PROFIBUS interface
2. Confirm with "OK".
The dialog is closed, the SIMOTION D4x5 is created in the project navigator, and HW Config
is started automatically (if parameterized).
A PROFIBUS subnet with factory settings (1.5 MBit/s transmission rate) is created
automatically.
The PG/PC is now connected to the SIMOTION D4x5 via PROFIBUS. You can configure
and parameterize your system.

Note
If you do not use the factory settings, you must configure the PROFIBUS interfaces in HW
Config.

Parameter assignment / addressing
6.2 Creating a project and configuring communication
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 111
Inserting a further SIMOTION device
If you insert a further SIMOTION device using "Insert SIMOTION device", the PG/PC
interface selection dialog box is not displayed. A further SIMOTION device is automatically
connected to the PG/PC via PROFIBUS and a new unique DP address is calculated
(address 4, 5 ... until 125 is reached).
Additional references
Further information on the topic of "Going online" can be found:
In the online help via the "Contents" tab at
"Diagnostics" > "Service and diagnostics" > "Overview of service and
diagnostics options" > "Part III" > "Go online"
"Insert device and connect to target system" > "Go online/offline"
On the Internet at http://support.automation.siemens.com/WW/view/en/22016709
(http://support.automation.siemens.com/WW/view/en/22016709)
In SIMOTION Utilities & Applications, FAQ "Online connections to SIMOTION devices"
SIMOTION Utilities & Applications is part of the scope of delivery of SIMOTION SCOUT.
See also
Establishing a PG/PC assignment (Page 123)
6.2.3 Configuring the Ethernet PG/PC interface
Requirement
The following requirements must be satisfied in order to configure the PG/PC interface:
You have completed the "Insert SIMOTION device" dialog box with "OK".
A PG/PC has not yet been configured in the project.
If these requirements have been satisfied, you can configure the interface for the PG/PC
connection in the "Interface Selection - D4x5" dialog.
Proceed as follows to configure the Ethernet interface:
Parameter assignment / addressing
6.2 Creating a project and configuring communication
SIMOTION D4x5
112 Commissioning and Hardware Installation Manual, 11/2010
Procedure
1. In the "Select Interface - D4x5 dialog", select "Ethernet IE2/NET (X130)".

Figure 6-3 Configuring an Ethernet Interface
2. Select the interface parameter assignment that you would like to use to go online, and
confirm with "OK".
The dialog is closed, the SIMOTION D4x5 is created in the project navigator, and HW Config
is started automatically (if parameterized).
An Ethernet subnet with factory settings is created automatically. (Factory settings, see
Section Properties of Ethernet interfaces (Page 125).)
Your PG/PC is now connected to the SIMOTION D4x5 the Ethernet. You can configure and
parameterize your system.

Note
If you want to change the default settings for IP addresses and the transmission rate, you
must configure the Ethernet interfaces in HW Config and NetPro.

Please make sure that the PG/PC and SIMOTION D4x5 are located in the same subnet and
that S7 online access has been activated (PG/PC connection must be yellow and bold in
NetPro).
Inserting a further SIMOTION device
If you insert a further SIMOTION device using "Insert SIMOTION device", the PG/PC
interface selection dialog box is not displayed. A second SIMOTION device is automatically
connected to the PG/PC via Ethernet, and a new unique IP address is calculated (last digit +
1, until 255 is reached).
Parameter assignment / addressing
6.2 Creating a project and configuring communication
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 113
Additional references
Further information on the topic of "Going online" can be found:
In the online help via the "Contents" tab at
"Diagnostics" "Service and diagnostics" "Overview of service and diagnostics
options" "Part III" "Go online"
"Insert device and connect to target system" "Go online/offline"
On the Internet at http://support.automation.siemens.com/WW/view/en/22016709
In SIMOTION Utilities & Applications, FAQ "Online connections to SIMOTION devices"
SIMOTION Utilities & Applications is part of the scope of delivery of SIMOTION SCOUT.
See also
Establishing a PG/PC assignment (Page 123)
6.2.4 Representation of SIMOTION D4x5 in HW Config
Once you have created a project and inserted a SIMOTION D4x5 as a module, HW Config
opens automatically (if parameterized).
In HW Config the SIMOTION D4x5 units are shown with the SINAMICS Integrated and the
interfaces.

Figure 6-4 Representation of SIMOTION D4x5 in HW Config
Parameter assignment / addressing
6.3 Configuring PROFIBUS DP
SIMOTION D4x5
114 Commissioning and Hardware Installation Manual, 11/2010
6.3 Configuring PROFIBUS DP
6.3.1 General information about communication via PROFIBUS DP
Definition of PROFIBUS DP
PROFIBUS DP is an international, open field bus standard specified in the European field
bus Standard EN 50170 Part 2. PROFIBUS DP is optimized for fast, time-critical data
transmissions at the field level.
Components communicating by means of PROFIBUS DP are classified as master or slave
components.
Master (active bus node):
Components that represent a master on the bus define data transfer along the bus, and
are therefore known as active bus nodes.
Masters components are divided into two classes:
DP master class 1 (DPMC1):
Central master devices are thus designated, which exchange information with the
slaves in specified message cycles.
Examples: SIMOTION D435, C240, P350, SIMATIC S7, etc.
DP master class 2 (DPMC2):
These are devices for configuration, commissioning, and operator control and
monitoring while the bus is in operation.
Examples: Programming devices, operator control/monitoring devices
Slaves (passive bus nodes):
These devices may only receive, acknowledge and transfer messages to a master when
so requested.
Examples: SINAMICS drives, I/O modules
Functions on PROFIBUS DP
The functional scope can differ between DP masters and DP slaves. The functional scope is
different for DP-V0, DP-V1 and DP-V2.
These functions on the PROFIBUS DP are characterized by:
Configurable equidistant isochronous PROFIBUS cycle
Synchronization of slaves by the master by means of a global control message frame in
each cycle clock
Independent maintenance of the equidistant cycle clock by the slaves in the event of a
short-term communication failure
Parameter assignment / addressing
6.3 Configuring PROFIBUS DP
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 115
Additional references
You will find additional information about PROFIBUS DP in the SIMOTION Communication
System Manual.
See also
Connection rules in the PROFIBUS subnet (Page 69)
6.3.2 Operating SIMOTION D4x5 on PROFIBUS DP.
PROFIBUS DP interface (X126, X136)
SIMOTION D4x5 provides two interfaces for connection on the PROFIBUS DP.
Transmission rates up to 12 Mbit/s are possible. Both interfaces can be operated
isochronously.
The X136 interface can also be used as an MPI interface.
As supplied, both PROFIBUS DP interfaces are preset as a master with address 2 and a
transmission rate of 1.5 Mbit/s. The PROFIBUS DP network is automatically created for this
setting.
However, other settings can also be configured. This requires that you configure the network
manually using HW Config and NetPro.

Note
Communication with the SINAMICS Integrated of a D4x5 or CX32 is always equidistant.
Here, SIMOTION D4x5 is the master and the SINAMICS Integrated drives are slaves.

Parameter assignment / addressing
6.3 Configuring PROFIBUS DP
SIMOTION D4x5
116 Commissioning and Hardware Installation Manual, 11/2010
Master-slave configuration
The master/slave configuration can be used, for example, to establish hierarchical
PROFIBUS networks that can be used to implement a modular machine concept.
Table 6- 1 Master-slave configuration
X126 X136 Note Actions in the application
DP slave,
isochronous
DP master,
isochronous
Application synchronized to DP master (X136), application
controls synchronization to DP slave (X126)
Internal drive is synchronous with external cycle clock
Cycle clock DP-136 = cycle clock DP Integrated
DP master/DP slave
synchronization
mechanisms
DP master,
isochronous
DP slave,
isochronous
Application synchronized to DP master (X126), application
controls synchronization to DP slave (X136)
Internal drive is synchronous with external cycle clock
Cycle clock DP-126 = cycle clock DP Integrated
DP master/DP slave
synchronization
mechanisms
DP slave,
isochronous
DP master, not
isochronous
Application synchronized to DP slave (X126)
(can be monitored by the application)
Internal drive is synchronous with X126
DP slave
synchronization
mechanisms
DP master, not
isochronous
DP slave,
isochronous
Application synchronized to DP slave (X136)
(can be monitored by the application)
Internal drive is synchronous with X136
DP slave
synchronization
mechanisms
DP master,
isochronous
DP master,
isochronous
Application synchronized to DP master (X126, X136)
Internal drive is synchronous with external cycle clock
Cycle clock DP-126 = cycle clock DP-136 = cycle clock
DP Integrated
None
DP master,
isochronous
DP master, not
isochronous
Application synchronized to DP master (X126)
Internal drive is synchronous with X126
Cycle clock DP-126 = cycle clock DP Integrated
None
DP master,
isochronous
DP slave, not
isochronous
Application synchronized to DP master (X126)
Internal drive is synchronous with X126
Cycle clock DP-126 = cycle clock DP Integrated
None
DP master, not
isochronous
DP master,
isochronous
Application synchronized to DP master (X136)
Internal drive is synchronous with X136
Cycle clock DP-136 = cycle clock DP Integrated
None
DP slave, not
isochronous
DP master,
isochronous
Application synchronized to DP master (X136)
Internal drive is synchronous with X136
Cycle clock DP-136 = cycle clock DP Integrated
None
DP master, not
isochronous
DP master, not
isochronous
Application synchronized to internal drive cycle clock None
DP slave, not
isochronous
DP master, not
isochronous
Application synchronized to internal drive cycle clock None
DP master, not
isochronous
DP slave, not
isochronous
Application synchronized to internal drive cycle clock None
DP slave, not
isochronous
DP slave, not
isochronous
Application synchronized to internal drive cycle clock None
Parameter assignment / addressing
6.3 Configuring PROFIBUS DP
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 117
X126 X136 Note Actions in the application
DP slave,
isochronous
DP slave, not
isochronous
Application synchronized to DP slave (X126) (can be
monitored by the application)
Internal drive is synchronous with X126
DP slave
synchronization
mechanisms
DP slave, not
isochronous
DP slave,
isochronous
Application synchronized to DP slave (X136)
(can be monitored by the application)
Internal drive is synchronous with X136
DP slave
synchronization
mechanisms
For detailed information about controlling synchronization across the application, see the
Basic Functions for Modular Machines Description of Functions.
Alternatively, the X136 interface can be used as an MPI interface with a transmission rate of
19.2 kbit/s up to 12 Mbit/s.
6.3.3 Assignment of the PROFIBUS addresses in HW Config
Assigning PROFIBUS addresses
In order for all devices to communicate with each other, you must assign a PROFIBUS
address to each device before connecting them:

Note
Before you assign any PROFIBUS addresses, please remember that all addresses must be
unique on the PROFIBUS subnet.

You set these PROFIBUS addresses individually for each device with the PG/PC using HW
Config. Some PROFIBUS DP slaves have a switch for this purpose.

Note
The PROFIBUS addresses set at the devices using these switches must correspond with the
address settings in HW Config.

Recommendation for PROFIBUS addresses
Reserve PROFIBUS address "0" for a service programming device and "1" for a service HMI
device, which will be connected to the subnet if required.
Recommendation for the PROFIBUS address of the SIMOTION D4x5 in case of
replacement or service:
Reserve address "2" for a SIMOTION D4x5. This prevents duplicate addresses from
occurring when a SIMOTION D4x5 is installed in the subnet using default settings (for
example, when replacing a SIMOTION D4x5). You should therefore assign addresses
greater than "2" to additional units on the subnet.
Parameter assignment / addressing
6.3 Configuring PROFIBUS DP
SIMOTION D4x5
118 Commissioning and Hardware Installation Manual, 11/2010
See also
Connection rules in the PROFIBUS subnet (Page 69)
6.3.4 Setting the DP cycle and system cycle clocks
All cycle clocks for SIMOTION D4x5 are based on the DP cycle of SINAMICS Integrated,
which must be set in HW Config.
To do so, click the SINAMICS block on the integrated PROFIBUS. The "DP Slave
Properties" dialog box opens. You can adjust the DP cycle of the SINAMICS Integrated on
the "Isochronous mode" tab.
Table 6- 2 Range of values for SIMOTION D4x5
D425 D435 D445/D445-1
DP cycle 1 ms 1 ms 0.5 ms
Grid 0.125 ms 0.125 ms 0.125 ms
Min. IPO cycle 2 ms 1 ms 0.5 ms

External DP interfaces can only be operated with a DP cycle of 1 ms.
The SINAMICS Integrated always runs in isochronous mode. The DP cycle setting of the
SINAMICS Integrated is displayed as the "Bus cycle clock" in the "System Cycle Clocks"
dialog box. In SIMOTION SCOUT, select SIMOTION D4x5 and then select the "Set System
Cycle Clocks" option in the "Target System" > "Expert" menu item.
The table below shows the possible ratio settings for the SIMOTION D4x5 system cycle
clocks based on the bus cycle clock.
Table 6- 3 Ratios of system cycle clocks
Bus cycle clock: Servo cycle clock Servo cycle clock: IPO cycle Servo cycle clock: IPO 2
cycle clock
1:1 1:4, 1:8 1:1 1:6 1:2 1:64

In addition, if the DP interfaces (DP1/DP2) are configured as equidistant master interfaces,
you must set both DP cycles equal to the bus cycle clock of the SINAMICS Integrated in HW
Config.
If the DP interfaces (DP1/DP2) are operated as the master, the system cycle clocks are
obtained from an internal cycle clock of the module. Of the two DP interfaces (DP1/DP2), no
more than one can also be operated as an isochronous slave interface. In this case, the
system cycle clocks are obtained from the cycle clock of the slave interface.
As a result, the task system of SIMOTION and SINAMICS Integrated runs synchronously to
the slave cycle clock. This assumes that a slave cycle clock exists and synchronization with
the slave cycle clock has been achieved. If this is not the case, the system cycle clocks are
acquired from an internal replacement clock.
Parameter assignment / addressing
6.3 Configuring PROFIBUS DP
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 119
When the project is downloaded, the cycle clock configuration is downloaded to the
SIMOTION D4x5 and automatically set according to the specifications.
See also
Setting a send cycle clock and a system cycle clock (Page 132)
Settings for DP slave properties (Page 190)
6.3.5 Cycle clock scaling of external PROFIBUS interface to internal PROFIBUS
interface
Definition
Cycle clock scaling means that an external PROFIBUS interface of the SIMOTION D4x5
(X126/X136) can be operated in an integer multiple of the internal PROFIBUS interface. This
reduces the CPU load, thereby allowing you to operate more axes, for example. The settings
of the scaled cycle clocks for the external DP interfaces are made in HW Config.
Boundary conditions
The following boundary conditions are applicable to cycle clock scaling:
An external DP interface of D4x5 is used as an isochronous slave interface. Only in this
case can an integer cycle clock scaling of isochronous external DP slave interface to
internal interface be specified. This is checked during compilation and an error message
is output in the event of noncompliance. If the external DP interfaces are configured as
equidistant interfaces but none are configured as slaves and cycle clock scaling is
specified for these interfaces, an error is output during compilation.
For SERVO, IPO, and IPO2, settings can also be made for all permissible cycle clocks.
Master and slave axes can run in different IPO levels. Different cycle clocks and phase
offsets are tolerated by the system.


Note
The IPO cycle clock of the IPO in which the Synchronous Operation technology object
runs must be set equal to the cycle clock of the equidistant external DP slave interface.
The second external DP interface can be operated as an equidistant master (while the
other is an equidistant slave) in order to operate external drives, for example. In this case,
the cycle clock must be the same as the cycle clock of the internal PROFIBUS DP. If this
condition is not satisfied, an error message is output during compilation.
One or both external DP interfaces can also be operated as non-isochronous, free-
running interfaces. In this case, there is no effect on the cycle clock settings.
Parameter assignment / addressing
6.3 Configuring PROFIBUS DP
SIMOTION D4x5
120 Commissioning and Hardware Installation Manual, 11/2010
Example of an application
The system consists of a synchronous master (DP master) and at least one SIMOTION
D4x5 synchronous slave (DP slave). The synchronous master contains the master axis; the
synchronous slave contains the following axes:
The axes in SINAMICS Integrated of the D4x5 synchronous slave must exhibit high
performance with a servo cycle clock of 1 ms and an internal DP cycle of 1 ms. This
requires that the internal fast PROFIBUS DP be decoupled from the slower external
PROFIBUS DP.
The PROFIBUS DP has, for example, a cycle time of 4 ms due to the quantity framework
on the bus; in all cases, its cycle time exceeds that of the cycle clock of the internal DP
interface.
The master setpoints are transferred via the DP bus. Further nodes can also be
connected to the DP bus, e.g. DP drives, distributed I/Os, etc.
Slave interface X126
External DP
drive (optional)
External DP
drive
DP = 1 ms
Master interface
Synchronous master
(e.g. P350)
DP cycle clock = 4 ms
Servo = 4 ms
SlMOTlON D4x5
lnternal DP = 1 ms
Servo = 1 ms
lnternal drive
M
a
s
t
e
r

i
n
t
e
r
f
a
c
e

X
1
3
6
DP bus (master value bus) DP cycle clock = 4 ms
DP cycle
clock =
lnternal DP
Synchronous slave

Figure 6-5 Example application for a cycle clock scaling
Parameter assignment / addressing
6.3 Configuring PROFIBUS DP
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 121
6.3.6 Creating a new PROFIBUS subnet
Introduction
SIMOTION SCOUT is used to network the SIMOTION D4x5. During the configuration
process, the desired bus parameters can be set for the PROFIBUS DP interfaces.

Note
If a hardware configuration is loaded without a PROFIBUS network (DP1 or DP2) being
configured on the CPU, a new PROFIBUS address that was previously set in HW Config or
NETPRO will not be accepted by the CPU.

Requirement
You have created a project and have already inserted a SIMOTION D4x5.
Procedure
To create a new subnet, proceed as follows:
1. In the project navigator, double-click D4x5 to access HW Config.
2. In the SIMOTION D4x5 representation, double-click the interface for which you want to
create a PROFIBUS subnet.
The "DPx Properties" dialog box is opened.
3. Click "Properties" to show the "PROFIBUS Interface DPx" dialog box.
4. Click "New" to call the "Properties - New PROFIBUS Subnet" dialog.
5. Name the new subnet and enter the properties of the new subnet, such as transmission
rate, on the "Network Settings" tab.
6. Confirm with "OK" to accept the settings.
The new subnet is now displayed in the "Properties - PROFIBUS Interface DPx" dialog.
You can now connect the new subnet to the corresponding PROFIBUS interface.
Follow the same steps to configure the second PROFIBUS interface.
A graphical representation of the PROFIBUS subnet you have created is shown in HW
Config.
Parameter assignment / addressing
6.3 Configuring PROFIBUS DP
SIMOTION D4x5
122 Commissioning and Hardware Installation Manual, 11/2010
6.3.7 Modifying the data transmission rate
Introduction
You can modify the transmission rate in a PROFIBUS subnet in HW Config according to
your requirements.
Procedure
1. Open the project in SIMOTION SCOUT.
2. Double-click the device whose PROFIBUS subnet you want to configure.
HW Config is displayed showing the settings for this device.
3. In HW Config, double-click in the graphical display on the PROFIBUS network whose
transmission rate you want to configure.
The "Properties - DP Master System" dialog is displayed.
4. Click on "Properties" to display the "PROFIBUS Properties" dialog.
5. Select the required transmission rate on the "Network settings" tab.
If you wish to activate an equidistant bus cycle, the setting can be made under "Options".
6. Confirm with "OK".
7. Save and compile the new hardware configuration, and load it on the SIMOTION D.

Note
If you modify the transmission rate of the subnet over which you are operating the PG/PC,
the PG/PC loses its active designation. You must then reconfigure it manually in NetPro or
else you will no longer be able to go online by means of this PG/PC.



Note
PROFIBUS DP functionality is both equidistant and isochronous in nature. As such, it can
guarantee that bus cycles will have exactly the same length and ensures deterministic
behavior.
Applications: Connecting drives or synchronized I/O devices.

See also
Function Manual SIMOTION SCOUT Basic Functions, Chapter Isochronous I/O processing
on fieldbus systems
Parameter assignment / addressing
6.3 Configuring PROFIBUS DP
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 123
6.3.8 Establishing a PG/PC assignment
Introduction
A PG/PC is required to create projects for a SIMOTION D4x5 and download them to the
target device. The interface via which the PG/PC can be connected is polled during the
automatic communication configuration. If you change these settings, you must reestablish
the active designation of the PG/PC in NetPro. (The PG/PC connection must appear yellow
and bold in NetPro.)
Procedure
1. Open the project in SIMOTION SCOUT.
2. Click the "Open NetPro" button.
NetPro is accessed, and the configured network is graphically displayed. The PG/PC
connection to the configured network is shown in bold in a color other than yellow.
3. Double-click the PG/PC you would like to configure.
The "Properties - PG/PC" dialog will be displayed with the "Assignment" tab in
foreground.
4. Select the interface in the "Assigned" field and activate S7ONLINE access by clicking the
appropriate checkbox.
5. Click "OK" to accept the settings.
The PG/PC connection to the configured network is displayed again in bold and yellow.
6. Save and compile the changes and download them to the SIMOTION D4x5.
You can now go online via the PG/PC once again.
Alternatively, you can make the assignment in SIMOTION SCOUT by clicking the "Assign
PG/PC" button. This calls the properties window for PG/PC assignment, where you can
modify the assignment and "activate" it (S7ONLINE access).
Parameter assignment / addressing
6.4 Configuring an Ethernet subnet
SIMOTION D4x5
124 Commissioning and Hardware Installation Manual, 11/2010
6.4 Configuring an Ethernet subnet
6.4.1 Configuring an MPI bus
6.4.1.1 Operating the X136 interface as MPI
The X136 interface can also be used as an MPI interface, for example, to connect to an
external PG/PC.
When the X136 interface is used as an MPI bus, additional activation of a drive on this
interface is not possible.

Figure 6-6 Connection of D4x5 (using X136) and MPI bus component
6.4.1.2 MPI parameters
MPI bus addresses and data transmission rate
Every node on the MPI bus must have a bus address in the range 0 to 31.
The data transmission rate on the MPI bus can be set to any value for the SIMOTION D4x5.
Communication attempt unsuccessful
If communication cannot be established at all, or if it cannot be established with individual
nodes on the MPI bus, check the following elements:
Is the transmission rate setting for the D4x5 used for all nodes?
Are there any loose plug connections?
Are all bus segments terminated properly?
Bus segments that are not terminated properly will disrupt communication on the MPI
bus.
Parameter assignment / addressing
6.4 Configuring an Ethernet subnet
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 125
6.4.2 Properties of the Ethernet interfaces
Properties
SIMOTION D4x5 has two onboard Ethernet interfaces (X120 and X130). You can connect
an Industrial Ethernet with a transmission rate of 10/100 MBit/s to the 8-pin X120 and X130
RJ45 sockets.
There is no HUB/switch functionality, i.e. message frames are not forwarded from one
interface to the other. The interfaces belong to separate Ethernet subnets. SIMOTION D4x5
does not have any router functionality; it does not forward the message frames from one
subnet to another.
The features of the Ethernet interfaces are as follows:
TCP/IP timeout parameters can be set once for both interfaces.
The transmission rate/duplex can be set individually for the two interfaces.
The interfaces do not have autocrossing functionality.
Ethernet communication
SIMOTION D4x5 offers the following functions via Industrial Ethernet:
Communication with STEP 7, SIMOTION SCOUT, and SIMATIC NET OPC via a PG/PC
Communication via UDP (user datagram protocol) with other components, e.g. other
D4x5 devices
Communication with other devices via TCP/IP
Connection of SIMATIC HMI devices such as MP27x, MP37x, or PC-based HMIs
IT communication (SIMOTION IT DIAG, SIMOTION IT OPC XML-DA; as option:
SIMOTION IT Virtual Machine)
Routing
"Services via TCP" are supported for both Ethernet interfaces.
From the two Ethernet interfaces, S7 routing is possible to the
PROFIBUS interfaces and
PROFINET interfaces (as of V4.1 SP2).
As well as between the Ethernet interfaces
IP routing from one Ethernet interface to another, as well as from PROFINET to the Ethernet
interface and vice versa, are not possible.
You can find the MAC addresses on the nameplate located on the front of the SIMOTION
D4x5.
Parameter assignment / addressing
6.4 Configuring an Ethernet subnet
SIMOTION D4x5
126 Commissioning and Hardware Installation Manual, 11/2010
See also
Further information about routing and the differences between IP and S7 routing can be
found in the Communication System Manual.
Default Ethernet addresses
The following addresses are set on the module when shipped:
X120 (IE1/OP)
IP address: 192.168.214.1
Subnet mask: 255.255.255.0
Router address: 0.0.0.0

X130 (IE2/NET)
IP address: 169.254.11.22
Subnet mask: 255.255.0.0
Router address: 0.0.0.0


Note
The IP addresses 192.168.215.240 to 192.168.215.255 are reserved for internal
communication in SIMOTION D4x5 (subnet mask 255.255.255.240). When configuring
the external Ethernet interfaces (X120 and X130) it has to be observed that the internal
addresses are not inside their network. (In IP, the network is defined as an AND link of IP
address and subnet mask.)


Note
If you want to go online via Ethernet, you have to make sure that the connection from
PG/PC to SIMOTION D4x5 is active. You can check this in NetPro. A description of how
to switch a connection to active again can be found in Establishing the PG/PC
assignment (Page 123).
Separate Ethernet interfaces
The two Ethernet interfaces are entirely separate and must be connected to two different
networks.
The two Ethernet interfaces support:
S7 routing (as of V4.1 SP2)
No IP routing
SIMOTION D4x5 can, therefore, be connected to the machine user's internal company
network with one interface and the second can be used, for example, by the machine
manufacturer for the purpose of remote maintenance.
Parameter assignment / addressing
6.4 Configuring an Ethernet subnet
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 127
The Ethernet connection of the D4x5 can be configured in HW Config. Proceed as follows to
do this:
1. Open your project.
2. Open HW Config. Double-click the D4x5 module to open the "Properties - D4x5" dialog
box.
3. You can configure the Ethernet connection in the "Extended Ethernet" tab.
Recommendation: Use the default setting "Automatic setting". With Automatic setting, the
baud rate and duplex operating mode are automatically aligned with the connection
partner.
4. Close the "Properties - D4x5" dialog with "OK".
5. Save and compile the modified hardware configuration.
6. Load the new hardware configuration to the SIMOTION D4x5 via PROFIBUS
DP/Ethernet.
For additional information, refer to the
SIMATIC NET Industrial Twisted Pair and Fiber Optic Networks Manual.
See the list of references for the order number (this is a separate document).
For further information about the cabling spectrum for Ethernet, see the
Industrial Communication IK PI catalog.
6.4.3 Configuring Ethernet addresses in HW Config
Requirement
For configuration using Industrial Ethernet, SIMOTION D4x5 must be provided with an IP
address, the subnet mask, and the router address.

Note
Only one router may be configured.

Procedure
To configure and transfer Ethernet addresses to the D4x5, proceed as follows:
1. Open your project.
2. Open HW Config. Double-click the interface to be configured to open the "Properties"
dialog box.
3. On the "General" tab, click the "Properties" button of the Ethernet interface. The
"Properties - Ethernet Interface" dialog is displayed.
4. Click the "New" button. The "New Industrial Ethernet" subnet dialog is displayed. In this
dialog box, you can change the name of the new subnet or confirm the default setting
with "OK".
Parameter assignment / addressing
6.4 Configuring an Ethernet subnet
SIMOTION D4x5
128 Commissioning and Hardware Installation Manual, 11/2010
5. The newly created Ethernet subnet is now displayed under "Subnet" in the "Properties -
Ethernet Interface" dialog box and must be selected.
6. In this dialog box, enter the required addresses for "IP Address" and "Subnet". Under
"Router", choose whether a router is to be used. If using a router, enter the router
address.
7. Confirm this dialog box with "OK".
8. Close the "Properties" dialog by clicking "OK".
9. To configure the second Ethernet interface, open the "Properties" dialog of the second
interface and repeat Steps 3 to 7.
10. Save and compile the modified hardware configuration.
11. Load the new hardware configuration to the SIMOTION D4x5 via PROFIBUS
DP/Ethernet.
6.4.4 Reading out IP and MAC address
Requirement
To read out the IP and MAC addresses, the following requirements must be met:
SIMOTION D4x5 is wired.
You have assigned the communication parameters.
You are online.
Procedure
The IP addresses and MAC addresses of SIMOTION D4x5 can be displayed as follows via
SIMOTION SCOUT.
1. Right-click the module.
2. Select "Target Device" > "Device Diagnostics" in the context menu.
The examples below show how addresses are displayed:
X120 (IE1/OP)
Active MAC Address: 08-00-06-73-25-3E
IP address: 192.168.214.1
Subnet mask: 255.255.255.0
Standard gateway: No router used
X130 (IE2/NET)
Active MAC Address: 08-00-06-73-25-3F
IP address: 169.254.11.22
Parameter assignment / addressing
6.5 Configuring PROFINET IO
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 129
Subnet mask: 255.255.0.0
Standard gateway: No router used
As an alternative, you can set the IP address as follows:
By selecting "Project" > "Accessible nodes" in SIMOTION SCOUT or
By calling "Target system" > "Ethernet" > "Edit Ethernet Node..." in HW Config and
browsing to "Online accessible nodes".
Using the system function _getIpConfig


Note
The MAC address is listed on the nameplate on the front of the module.
6.5 Configuring PROFINET IO
6.5.1 General information about communication via PROFINET IO
Communication cycle
In PROFINET, the communication cycle is subdivided into different, time-specific intervals.
The first interval is used for isochronous real-time communication (IRT), followed by real-
time communication (RT) and standard TCP/IP communication. The bandwidth reservation
for IRT ensures that RT communication and standard communication have no effect on the
transmission of IRT message frames, which are important for motion-control applications.
The following figure shows how the PROFINET communication cycle is divided into
isochronous real-time communication (IRT), real-time communication (RT), and standard
TCP/IP communication.
Parameter assignment / addressing
6.5 Configuring PROFINET IO
SIMOTION D4x5
130 Commissioning and Hardware Installation Manual, 11/2010
lRT interval
TCP/lP
lRT
interval TCP/lP
lRT interval
TCP/lP
lsochronous communication RT communication
Standard
communication
Cycle 1 Cycle 2
= time window
Cycle n
lRT data RT Data TCP/lP data

Figure 6-7 PROFINET communication cycle
Isochronous realtime Ethernet
STEP 7 V5.4 and higher can be used to configure PROFINET devices supporting data
exchange via isochronous real-time Ethernet (IRT). IRT message frames are transferred
deterministically via planned communication paths in a defined sequence to achieve the best
possible synchronism and performance.
IRT requires special network components supporting a planned data transmission.
Equidistance and Cycle Clock Synchronization
What is possible for PROFIBUS DP with isochronous bus cycles and clock synchronization,
also functions for PROFINET IO.
For PROFIBUS DP, in isochronous operation all nodes are synchronized using a global
control signal created by the DP master.
In PROFINET IO with IRT, a sync master generates a signal to which sync slaves
synchronize themselves. Sync master and sync slaves belong to a sync domain which is
assigned a name via configuration. The role of the sync master can in principle be played by
an I/O controller as well as an I/O device. A sync domain has exactly one sync master.
Context: Sync domain and I/O systems
An important fact is that sync domains do not need to be limited to one PROFINET IO
system: The devices of several I/O systems can be synchronized by a single sync master,
provided they are connected to the same Ethernet subnet.
The following applies the other way around: An I/O system must only belong to a single sync
domain.
Parameter assignment / addressing
6.5 Configuring PROFINET IO
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 131
Signal propagation delays not negligible
For the extremely exact synchronization interval, line lengths, namely the associated delay
times, must be taken into consideration. You can use a topology editor to enter the
properties of the lines among the ports of the switches. STEP 7 uses this data and the other
configuration data to calculate the optimized process of the IRT communication and the
resulting update time.
IRT runs in parallel to realtime and TCP/IP communication
Apart from IRT communication for which a defined bandwidth is reserved within the update
time, RT communication and TCP/IP communication are also permitted within the update
time.
With RT communication (real-time communication), the cyclic data is transferred between IO
controller and IO device, though without "best possible synchronism".
With non-synchronized IO devices, data is exchanged automatically via RT communication.
Due to the fact that TCP/IP communication is also possible, other non-realtime data, e.g.
configuration data or diagnostic data, can be transported.
PROFINET IO controller
Typically, the function of a PROFINET IO controller is taken on by controllers (e.g.
SIMOTION C/P/D, SIMATIC S7 CPUs, ...).
The PROFINET IO controller takes on the master function for I/O data communication of the
distributed field devices. The function is comparable to a PROFIBUS DP master class 1.
PROFINET IO device
Distributed field devices such as I/Os, drives (e.g. SINAMICS S120 with CBE20), or operator
terminals are designated as IO devices. The function is comparable to a
PROFIBUS DP slave.
Delivery condition
In the delivery condition the CBE30 does not have an IP address or a subnet mask.
Parameter assignment / addressing
6.5 Configuring PROFINET IO
SIMOTION D4x5
132 Commissioning and Hardware Installation Manual, 11/2010
6.5.2 Setting a send cycle clock and a system cycle clock
Setting the DP cycle in HW Config
All cycle clocks for SIMOTION D4x5 are based on the DP cycle of SINAMICS Integrated,
which must be set in HW Config.
To do so, click the SINAMICS block on the integrated PROFIBUS. The "DP Slave Property"
dialog box opens. You can adjust the DP cycle of the SINAMICS Integrated on the
"Isochronous mode" tab. See also Additional information on configuring the SINAMICS
Integrated (Page 190).
Table 6- 4 Range of values for SIMOTION D4x5
D425 D435 D445/D445-1
DP cycle 1 ms 1 ms 0.5 ms (DP internal)
1.0 ms (DP external)
Grid 0.125 ms 0.125 ms 0.125 ms
IPO cycle 2 ms 1 ms 0.5 ms
Setting the send cycle clock in HW Config
The send cycle clock for PROFINET IO must be set in the "Domain Management" dialog in
HW Config. To do this, select the "Edit" > "PROFINET IO" > "Domain management ..." menu
command in HW Config and set the desired cycle clock.
The configured PROFINET send cycle clock is displayed in SIMOTION SCOUT as the "Bus
Cycle Clock" in the "System Cycle Clocks - D4x5" dialog. Select SIMOTION D4x5 and then
select the "Set System Cycle Clocks" option in the "Target System" > "Expert" menu item.
The PROFINET interface can be operated with a send cycle clock in the range of: 0.5 ms
send cycle clock 4 ms. The smallest configurable grid is 0.125 ms.
If there are IO devices with RT class "RT" in a sync domain, it is only possible to set the
send cycle clocks 0.5 ms, 1 ms, 2 ms and 4 ms.
Parameter assignment / addressing
6.5 Configuring PROFINET IO
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 133
Cycle clock scaling
When PROFINET is operated isochronously, the servo cycle clock must always correspond
to the PROFIBUS cycle clock. The servo cycle clock and the PROFIBUS cycle clock can be
scaled to the PROFINET cycle clock.
Example:
PROFINET sending cycle = 0.5 ms
PROFIBUS cycle clock = position control cycle clock =1 ms
The PROFIBUS cycle clock can operated relative to the PROFINET cycle clock at a ratio of
1:1 to 1:16.
The table below shows the possible ratio settings for the SIMOTION D4x5 system cycle
clocks based on the DP cycle of SINAMICS Integrated or PROFINET send cycle clock.
Table 6- 5 Ratios of system cycle clocks
DP cycle/send cycle clock: Servo cycle clock Servo cycle clock: IPO
cycle clock
IPO cycle clock: IPO 2
cycle clock
1:1 ... 1:4, 1:6, 1:8, 1:10, 1:12, 1:14, 1:16 1:1 ... 1:6 1:2 ... 1:64
6.5.3 Properties of PROFINET
Properties
In order to work with SIMOTION D4x5 over PROFINET IO, the Communication Board
Ethernet CBE30 must be inserted into the option slot on the SIMOTION D4x5.
The PROFINET IO IRT module CBE30 supports parallel operation of:
IRT - isochronous real-time Ethernet
Operation of IRT I/O (e.g. ET 200S)
Operation of a SINAMICS S120 as an IRT device
RT - realtime Ethernet
Operation of RT I/O (e.g. ET 200S, ET 200pro, etc.)
Operation of a SINAMICS S120 as an RT device
TCP/IP, UDP, HTTP, standard Ethernet services


Note
For mixed operation of IRT and RT, make sure that the IRT-compatible devices form what
is referred to as an IRT domain; i.e. there must not be any non-IRT devices on the data
transmission link between the IRT devices.
Parameter assignment / addressing
6.5 Configuring PROFINET IO
SIMOTION D4x5
134 Commissioning and Hardware Installation Manual, 11/2010
Additional references
You will find an overview of the specific properties of PROFINET IO on SIMOTION D4x5 in
the SIMOTION Communication System Manual.
6.5.4 Configuration tasks
Configuration of PROFINET involves the following steps:
1. Insert the SIMOTION D4x5.
2. Insert and configure the CBE30 module in HW Config.
3. Create a topology: Here, you specify how the individual ports of the PROFINET IO
devices are interconnected.
4. Configure the sync domain: Here, you specify which PROFINET nodes are sync masters
(clock generator) and sync slaves.
5. Specify the send clock: Describes the time during which a PROFINET IO device
exchanges user data with the PROFINET IO controller.
6. Configure the direct data exchange: With the direct data exchange you define which
address areas are to be used for sending and which for receiving.
Additional references
You will find a detailed description of each configuration step in the chapter entitled
"Configuring PROFINET IO with SIMOTION" of the SIMOTION Communication System
Manual.

SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 135
Commissioning (software) 7
7.1 Overview of commissioning
Requirements
The following requirements must be fulfilled in order to commission the SIMOTION D:
The system has been connected and wired.
The SIMOTION D has been switched on and powered up (STOP mode).
SIMOTION SCOUT (with integrated STARTER) has been installed and powered up on
the PG/PC.
The communication and networks have been configured.
You have created a project and inserted a SIMOTION D in the project.


Note
The order numbers (MLFB) of the SINAMICS S120 components must be available.
You need these order numbers when setting up a SIMOTION project to verify that the
components selected from the hardware catalog in the HW Config application correspond
to the ones used in the system.
7.1.1 Symbolic assignment / adaptation
Symbolic assignment
As of V4.2, SIMOTION supports the symbolic assignment on SINAMICS drive objects (DOs)
during the configuration of technology objects (TO) and I/Os.
This simplifies the configuration of the technological relationships including the
communication between controller and drive.
With the symbolic assignment:
Only suitable assignment partners are offered in an assignment dialog box
Commmunication between axis and drive is set up automatically by the engineering
system and the required PROFIdrive axis message frames as well as the used addresses
set up
Message frames are extended and interconnections created automatically in the drive
depending on the selected TO technology (e.g. SINAMICS Safety Integrated)
Commissioning (software)
7.1 Overview of commissioning
SIMOTION D4x5
136 Commissioning and Hardware Installation Manual, 11/2010
Axis and drive configuration can initially be carried out independently of one another
Communication connections are established automatically during the configuration of I/O
variables on SINAMICS I/Os (message frames are set up automatically, the I/Os
interconnected to the message frame and the addresses set up)
Apart from the symbolic assignment, no further configuration is required for the
communication. As addresses no longer have to be configured, the connection is retained
even with address offsets.

Note
During the configuration of drive objects (DO drive, DO encoder, ...) as well as in the
Message Frame Configuration dialog box (see Section Message frame configuration
(Page 216)), you can deactivate the automatic message frame configuration and the
automatic message frame adaptation.
As many of the previously described advantages are lost through a deactivation, we
recommend that a deactivation only be performed in exceptional circumstances.

The symbolic assignment enables an independent configuration of the axes on the
SIMOTION side and the drives on the SINAMICS side.
This enables, for example:
The PLC and motion control functions to be completely configured by a programmer even
without drive know-how using technology objects (e.g. TO axis) and loaded to the device
The drives to be separately configured and optimized by a drive expert and
The technology objects to be symbolically assigned later to the drive objects via an
interconnection dialog box


Note
The previous methods of drive, axis and I/O configuration are still available.
The symbolic assignment must be deactivated for these methods.
For newly created projects, the symbolic assignment is used per default.
If projects < V4.2 are upgraded, the symbolic assignment is deactivated per default and
must be activated when required.
The symbolic assignment can be activated/deactivated in SIMOTION SCOUT via the
menu
"Project" > "Use symbolic assignment".
Activating the symbolic assignment later
The symbolic assignment simplifies the configuration of the technological relationships
including the communication between controller and drive significantly. The names of the
symbolic assignments in plain text is also advantageous for project maintenance. The
symbolic assignment is therefore recommended for new projects as of V4.2 and is
automatically active.
If symbolic assignment is used in a project, message frames, interconnections and
addresses are automatically created by the engineering system per default.
Commissioning (software)
7.1 Overview of commissioning
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 137
The engineering system sets the "optimal" PROFIdrive message frames and message frame
extensions for the system, makes the required BICO interconnections and determines the
addresses.
It is also possible to change updated projects to symbolic assignment and this must be
decided individually, as follow-up work may be required.
Extensive follow-up work is usually required, particularly for free message frame
configurations (e.g. for TB30, TM15 DI/DO, TM31).

Note
If symbolic assignment is subsequently activated for a project in which message frames
have already been configured and interconnected, these can be changed together with the
BICO interconnections!
For this reason, make a backup copy of your project before activating the symbolic
assignment.
Further details can be found in the SIMOTION SCOUT Basic Functions Function Manual.

Assigning a drive later
You can create an axis in SIMOTION SCOUT and assign it later to a drive. You can thus
load your user program to the controller and (with the exception of the non-existent drives)
test it.
Compared to a procedure with temporarily created "virtual axes", "axes without assigned
drive" have the advantage that the configuration data is completely available and do not
require a "virtual axis -> real axis" reconfiguration.
Adaptation
In addition to the symbolic assignment, the automatic adaptation facilitates the configuration
of SINAMICS S110/S120 data as of SIMOTION V4.2. During power-up of the SIMOTION
devices, reference variables as well as drive and encoder data of the SINAMICS S110/S120
are automatically taken over for the configuration data of the SIMOTION technology objects
"TO axis" and "TO externalEncoder". This data no longer has to be entered in SIMOTION.
For further information refer to
SIMOTION SCOUT Basic Functions Function Manual
TO Axis Electric/Hydraulic, External Encoder Function Manual
Commissioning (software)
7.1 Overview of commissioning
SIMOTION D4x5
138 Commissioning and Hardware Installation Manual, 11/2010
Requirement
The symbolic assignment is supported by the TO axis, TO externalEncoder and the
TO outputCam, TO camTrack and TO measuringInput. The onboard I/Os of a SIMOTION D,
of a SINAMICS S110/S120 control unit as well as from a TB30 and selected terminal
modules can be interconnected symbolically.
Table 7- 1 Control units that support a symbolic assignment
Module Supports symbolic assignment
SIMOTION D4x5-2 As of SIMOTION V4.2
SIMOTION D410, D4x5 As of SIMOTION V4.2
Controller extension
CX32-2
CX32
As of SIMOTION V4.2
SINAMICS S110 CU305 As of SINAMICS V4.3
SINAMICS S120
CU310
CU320-2
CU320

As of SINAMICS V2.6.2
As of SINAMICS V4.3
As of SINAMICS V2.6.2
See also
Only the drive configuration by means of symbolic assignment is described in this
documentation.
The documentation of older SIMOTION versions can found on the Internet at
(http://support.automation.siemens.com/WW/view/en/40211807)
For further information on the configuration of the TO axis and TO externalEncoder, refer to
the TO Axis Electric/Hydraulic, External Encoder Function Manual.

Commissioning (software)
7.1 Overview of commissioning
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 139
7.1.2 Procedure when commissioning
Commissioning steps
This section shows you how to configure a system and test the configured drives and axes.
The commissioning steps are listed below. The sequence is only an example and can vary
depending on the supplementary conditions.
1. Configure the SINAMICS Integrated:
You can configure the integrated drives (SINAMICS Integrated) offline or online:
Offline configuration:
Performing D4x5 offline configuration (Page 141) and Performing CX32 offline
configuration (Page 180)
For offline configuration, all of the components and their order numbers must be
known.
Online configuration:
Performing D4x5 online configuration (Page 166) and Performing CX32 online
configuration (Page 183)
During online configuration, you can download all of the information from the
connected DRIVE-CLiQ components to your user project.


Note
The next two sections describe how a SIMOTION D4x5 including SINAMICS
Integrated is configured. The described procedure also applies when CX32 controller
extensions are used.
The Section "Configuring a CX32" also describes the step-by-step commissioning with
a CX32 controller extension. The advantage of a step-by-step configuration is that the
location and cause of an error are easier to identify.
2. Testing a drive with the drive control panel
3. Creating an axis with the axis wizard (Page 204)
4. Testing an axis with the axis control panel (Page 211)
5. Activating the infeed (line module) (Page 213)
6. Setting up addresses and message frames (Page 216)
7. Linking an additional encoder (optional) (Page 219)
8. Configuring drive-related I/Os (with symbolic assignment) (Page 226)
9. Configuring the technology (Page 230)
10. Optimizing the drive and controller (Page 238)
This section also contains additional configuration information, e.g. for vector drives, Safety
Integrated, etc.
Commissioning (software)
7.1 Overview of commissioning
SIMOTION D4x5
140 Commissioning and Hardware Installation Manual, 11/2010
See also
Testing a drive with the drive control panel (Page 200)
Creating and testing axes (Page 203)
7.1.3 Important functions for the project handling during commissioning
The following functions are very important for the project handling and commissioning:
Table 7- 2 Functions with their symbols
Symbol Function Effect

Save project and
compile all
Select Save project and compile all to save the
entire project and compile the project data (e.g.
programs) in an executable code.

Connect to selected
target devices
The online connection is established to the selected
target devices. Under "Target system" > "Select
target devices", you can set which target devices are
to go online.

Download project to
target system
Downloading programs to the SIMOTION device and
performing configuration for the SINAMICS
Integrated and any connected CX32 modules

Download CPU / drive
unit to target device
The configuration is only loaded to the device
selected in the project tree (which means that the
function needs to be performed separately for each
D4x5/CX32 and each SINAMICS Integrated).

Load CPU / drive unit
to PG
The unit's configuration is only loaded to the
programming device selected in the project tree
(which means that the function needs to be
performed separately for each D4x5/CX32 and each
SINAMICS Integrated).

Copy RAM to ROM Copying from RAM to ROM is only performed for the
device selected in the project tree (which means that
the function needs to be performed separately for
each D4x5/CX32 and each SINAMICS Integrated).
Commissioning (software)
7.2 Performing offline configuration for the D4x5
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 141


Note
Tips for going ONLINE:
In online operation, SCOUT attempts to conduct online operation with all hardware
components contained in the project. This means that the time needed for going online
increases.
We recommend that you make settings for SCOUT so that online operation is made only
with those components currently needed. The setting can be found at "Target system >
Select target devices ..." in the menu. The selection and deselection of the devices in the
online state can be made via the "Connect target device" context menu on the device.
This procedure is also advantageous when the configuration of the drive unit is completed.
Without going completely offline, the connection can be simply deselected via the context
menu on the drive unit.

7.2 Performing offline configuration for the D4x5
7.2.1 Overview
Introduction
In the offline configuration, the project is created without all the hardware components
(especially drives) being available. In this way, a SIMOTION project in the office environment
can be created up to a point where a basic project specification including a program exists.
You can then load the finished project to the SIMOTION D4x5 later and test it with the
drives.
Requirements
For offline configuration, all of the components and their order numbers must be known.
You have created a project in SIMOTION SCOUT and inserted a SIMOTION D4x5 into
the project in the hardware configuration.
You have configured the communication between the SIMOTION D4x5 and the PG/PC.
See Creating a project and configuring communication (Page 107).
Commissioning (software)
7.2 Performing offline configuration for the D4x5
SIMOTION D4x5
142 Commissioning and Hardware Installation Manual, 11/2010
Procedure
Offline configuration involves the following steps:
Accessing the drive wizard (Page 142)
Configuring components (Page 143)
Downloading the project to SIMOTION D4x5, by means of one of the following options:
Download to target system (Page 161)
Download to the CF card (Page 163)
Download incl. sources and additional data (Page 164)
Archiving a project to the CF card (zip file) (Page 165)

Note
During offline configuration, you can also configure the available option boards (TB30) and
terminal modules, e.g. TM41.

7.2.2 Accessing the drive wizard
Integrated drive
The SIMOTION D4x5 contains an integrated SINAMICS S120 drive device, which is
automatically inserted along with the SIMOTION D4x5 control unit in the project navigator.
The integrated drive must be operated in equidistant, isochronous mode using PROFIdrive-
compliant message frame types.
The drive wizard for the integrated starter is available in SIMOTION SCOUT for configuring
the integrated drive and its associated modules (e.g. SINAMICS S120 active line modules
and SINAMICS S120 motor modules).

Note
Take note of all the necessary safety precautions and rules governing connections, which
can be found in the latest SINAMICS S120 documentation on the SIMOTION SCOUT DVD.

Requirement
You have created a project and have already inserted a SIMOTION D4x5.
Commissioning (software)
7.2 Performing offline configuration for the D4x5
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 143
Procedure
To call the drive wizard for the configuration of your drive unit, double-click "Configure drive
unit" below "D4x5" > "SINAMICS Integrated" in the project navigator.
You can configure the following components:
Infeed (e.g. SINAMICS S120 active line module)
Drive
Power unit (e.g. SINAMICS S120 motor module)
Motor
Encoder
Option module
7.2.3 Configuring components
Requirement
You have inserted a SIMOTION D4x5 into the project, configured the communication, and
accessed the drive wizard by double-clicking "Configure Drive Unit" in the project navigator.

Note
An overview of permissible configurations, quantity structures and DRIVE-CLiQ topologies
can be found in the Commissioning Manual for SINAMICS S120.
It should be noted, for example, that mixed operation of servo and vector is not possible,
although mixed operation of servo and vector V/fis possible.
Failure to comply with the rules listed in this manual will result in errors that are not output
until the download is performed, rather than at the configuration stage.

Commissioning (software)
7.2 Performing offline configuration for the D4x5
SIMOTION D4x5
144 Commissioning and Hardware Installation Manual, 11/2010
Procedure
While executing the wizard you will be prompted to perform, for example, the following
configuration steps:
1. In the "Option Module" dialog box, select whether you want to use a TB30 as option
module.

Figure 7-1 Selecting an option module


Note
The TB30 is displayed as a drive object below the control unit in the project navigator and
can be configured there.
Commissioning (software)
7.2 Performing offline configuration for the D4x5
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 145
2. In the "Insert Infeed" dialog box", select whether you want to use an infeed with or without
a DRIVE-CLiQ connection. If the DC link has an external supply, select "No" (no
DRIVE-CLiQ connection).

Figure 7-2 Selecting an infeed with DRIVE-CLiQ connection


Note
If you have selected an uncontrolled infeed without a DRIVE-CLiQ connection, omit steps
3 to 6 below.

Commissioning (software)
7.2 Performing offline configuration for the D4x5
SIMOTION D4x5
146 Commissioning and Hardware Installation Manual, 11/2010
3. In the "Infeed Configuration" dialog box, enter a name for the drive object and select a
type for your infeed (e.g. Active Infeed).

Figure 7-3 Selecting the infeed type

4. Using the order number, select an infeed from the list. You can filter the information to
limit the number of infeeds displayed, by using "Type", for example.

Figure 7-4 Selecting an infeed

Commissioning (software)
7.2 Performing offline configuration for the D4x5
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 147
5. You can make additional settings for the infeed in the "Infeed Drive Object - Additional
Data" dialog box.

Figure 7-5 Making settings for the infeed
Commissioning (software)
7.2 Performing offline configuration for the D4x5
SIMOTION D4x5
148 Commissioning and Hardware Installation Manual, 11/2010
6. The communication for the control of the infeed is configured in the following dialog box.
It is recommended that these settings be made automatically by the engineering system.
You can also make the settings manually for the process data exchange by selecting
"User-defined".

Figure 7-6 Configuring the process data exchange for the infeed
If the automatic communication setting has been selected, SIMOTION SCOUT uses
PROFIdrive message frame 370 per default. This message frame is also used by the
system function _LineModule_control to control the infeed.
You can find further information on control of the infeed in Section Activating the infeed
(line module) (Page 213).
If you are using a CX32 controller extension, also refer to the information in Section
Interconnecting the infeed "Operation" signal on the CX32 (Page 185).
Commissioning (software)
7.2 Performing offline configuration for the D4x5
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 149
If you activate the line module with "Free message frame configuration using BICO", you
will have to connect the enabling signal via BICO. You will find information about
interconnecting signals with BICO technology in the SINAMICS S120 Commissioning
Manual.
7. Now configure the drive.

Figure 7-7 Configuring a drive

Commissioning (software)
7.2 Performing offline configuration for the D4x5
SIMOTION D4x5
150 Commissioning and Hardware Installation Manual, 11/2010
8. Enter a name for the drive and select the type of drive object (servo or vector).

Figure 7-8 Drive properties

9. In the "Control Structure" dialog, you can select the function modules and the control
type. Here, you can select "Vector" for the V/f control under "Drive objects type".

Figure 7-9 Closed-loop control structure

Commissioning (software)
7.2 Performing offline configuration for the D4x5
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 151
10. In the "Power Unit" dialog box, use the order number to select your motor module from
the list.

Figure 7-10 Selecting a power unit

Commissioning (software)
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152 Commissioning and Hardware Installation Manual, 11/2010
11. If you have selected an infeed without a DRIVE-CLiQ connection in step 2, a message
prompting you to wire the operation signal will appear. The next dialog allows you to
select the source of the infeed's operation signal.

Figure 7-11 Selecting the infeed operation signal
Commissioning (software)
7.2 Performing offline configuration for the D4x5
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 153
12. In the case of double motor modules, you need to specify the terminal to which the motor
is connected.
You specify the motor in the following dialog boxes:
Either by selecting a standard motor from the list
Or by entering the motor data
Or by automatically identifying the motor (motor with DRIVE-CLiQ interface)

Figure 7-12 Selecting a drive (1)


Note
Motors with DRIVE-CLiQ interface have an integrated encoder evaluation that is
connected to the motor module via a fully digital communication interface
(DRIVE-CLiQ).
In this way, motor encoder and temperature signals as well as electronic rating plate
data, such as unique ID numbers, rated data (voltage, current, torque) can be
transferred directly to the control unit.
Commissioning (software)
7.2 Performing offline configuration for the D4x5
SIMOTION D4x5
154 Commissioning and Hardware Installation Manual, 11/2010

Figure 7-13 Selecting a drive (2)

Commissioning (software)
7.2 Performing offline configuration for the D4x5
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 155
13. Selecting a motor holding brake (if available).

Figure 7-14 Selecting a motor holding brake.
Commissioning (software)
7.2 Performing offline configuration for the D4x5
SIMOTION D4x5
156 Commissioning and Hardware Installation Manual, 11/2010
14. If you are using a motor that is not equipped with a DRIVE-CLiQ interface, select the
encoder order number in the "Encoder Selection via Motor Order Number" dialog box.

Figure 7-15 Selecting a motor encoder (1)


Commissioning (software)
7.2 Performing offline configuration for the D4x5
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 157
Figure 7-16 Selecting a motor encoder (2)


Note
If required, you can configure a second or third encoder in the "Encoder" dialog box. You
can transfer a maximum of two encoder values to SIMOTION via the axis message
frame.
In the case of motors with a DRIVE-CLiQ interface, the motor encoder is identified
automatically. It is not necessary to enter encoder data in such cases (the dialog for
selecting Encoder 1 is grayed out and, therefore, inactive).

15. The communication for the control of the SINAMICS drive is configured in the following
dialog box.
It is recommended that these settings be made automatically by the engineering system.
You can also make the settings manually for the process data exchange by selecting
"User-defined".
Information about the manual setting options can be found in the online help and in the
manuals for the SINAMICS S120 drive system.
Commissioning (software)
7.2 Performing offline configuration for the D4x5
SIMOTION D4x5
158 Commissioning and Hardware Installation Manual, 11/2010

Figure 7-17 Configuring the process data exchange
After you have configured all of the settings in the drive wizard, the "Summary" dialog
displays a list of all settings. You can accept these settings with "Finish" or edit the
configuration of individual components using the "Back" button.
Commissioning (software)
7.2 Performing offline configuration for the D4x5
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 159

Figure 7-18 Finishing the drive
Commissioning (software)
7.2 Performing offline configuration for the D4x5
SIMOTION D4x5
160 Commissioning and Hardware Installation Manual, 11/2010
Result
The configured drive will appear in the project navigator.

Figure 7-19 Representation in the project navigator

Commissioning (software)
7.2 Performing offline configuration for the D4x5
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 161
You will find an overview of the configured SINAMICS components under
"SINAMICS_Integrated" > "Topology".

Figure 7-20 Displaying the topology

See also
If you configure the message frames for the infeed and drive manually, you can find detailed
information on the respective message frame types in the following:
Motion Control, TO Axis Electric/Hydraulic, External Encoder Function Manual
SINAMICS S120 Function Manual
7.2.4 Downloading a project into the target system
Requirement
You have configured the hardware. You now need to download the hardware configuration
and the entire SIMOTION project to the target system.
If you have not yet configured your SIMOTION project (i.e. created ST programs, assigned
execution levels, etc.), complete this step first.

Note
You can only perform a project download in the STOP mode and for all target devices with
which you are ONLINE. You cannot download to drives that cannot be configured in SCOUT,
e.g MASTERDRIVES. The project data is loaded to all the devices connected ONLINE and
their subordinate drive units (provided these are selected in the Target Device Selection
dialog box). This can only be done in STOP mode.

Commissioning (software)
7.2 Performing offline configuration for the D4x5
SIMOTION D4x5
162 Commissioning and Hardware Installation Manual, 11/2010
Procedure
1. Save and compile the project.
2. Go online.
3. To load the project, perform "Download project to target system".
The data must also be saved on the CF card to ensure that the project is retained in the
event of a power failure. The following options are available:
Perform the "Copy RAM to ROM..." function manually on the D4x5-and all drives
(SINAMICS Integrated, CX32, etc.).
In the "Download to Target System" dialog box, select the option "After loading, copy
RAM to ROM". You can change the default setting for this dialog box in "Options" >
"Settings" > "Download".

Figure 7-21 Download project to target system
The SIMOTION project is downloaded to the target system and the online connection to
the drives established automatically.


Note
Online access to the drives is not possible if HW Config is not loaded at the time you
initially connect to the target system.
Download HW Config first to enable online access to the drives.


Note
If you have deselected the "Drives" option under "Tools" > "Settings" > "Download" in
SIMOTION SCOUT, you must download the configuration separately to each drive
(SINAMICS Integrated, CX32, etc.).
To do this, select the drive (e.g. SINAMICS Integrated) in the project navigator and
perform "Download CPU / drive unit to target device".
For fast operation, we recommend that, in principle, the drives be deselected and a
download only performed when required.
4. To save the parameter calculations of the drive in the project, perform "Target device"
"Load CPU / drive unit to PG" for each drive.
Commissioning (software)
7.2 Performing offline configuration for the D4x5
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 163
7.2.5 Downloading a project to the CF card
Requirement
Loading a project created offline to the CF card has the advantage of being faster than a
download.
It should be noted, however, that the first system power-up will take longer, as the
SINAMICS Integrated and CX32 controller extension will perform one-off parameter
calculations. These are automatically backed up on the CF card.

Note
In order to save the project data via the PG/PC, you need a CF card adapter in which you
can insert the CF card. The CF card must be displayed as a removable storage device with
any drive letter in Windows Explorer.
If the CF card is not displayed, check the CF card adapter and contact the hotline if
necessary.

Procedure
You can use a card adapter to write the entire project to the CF card, even in offline mode. In
SIMOTION SCOUT, you can call the "Load into file system" function in the context menu of
the SIMOTION device.
1. Save and compile the project.
2. Switch the SIMOTION D4x5 off.
3. Remove the CF card and insert it into a card adapter. The card adapter must be
connected to a PG/PC.
4. In the SCOUT project, select the SIMOTION D4x5 device you wish to download to the
CF card.
5. Click "Load into file system" in the context menu. A dialog opens.
6. In the "Load into file system" dialog, select the "Save normally" option and click the
"Select target" button.
7. Select the target drive.
8. Confirm your entries with "OK". The data is written to the CF card.
Commissioning (software)
7.2 Performing offline configuration for the D4x5
SIMOTION D4x5
164 Commissioning and Hardware Installation Manual, 11/2010
9. Remove the CF card and insert it into the slot on the D4x5.
10. Switch the D4x5 on. The D4x5 powers up with the downloaded project.


Note
The components' firmware is upgraded or downgraded automatically based on the FW
version on the CF card and the FW version on the SINAMICS components (DRIVE-CLiQ
components, CBE30, PM340, etc.).
The update can take several minutes and its progress is tracked by corresponding
messages appearing in the alarm window of SIMOTION SCOUT.
A firmware update on DRIVE-CLiQ components is indicated by the RDY LED flashing red
and green:
FW update running: RDY LED flashes slowly (0.5 Hz)
FW update complete: RDY LED flashes quickly (2 Hz)
These flashing patterns are also displayed on the yellow RDY LED on the
SIMOTION D/CX32, and indicate that a FW update has been carried out on components
connected to the SIMOTION D/CX32 or that all components have completed the FW
update.
Go offline once all the FW updates have been completed. POWER ON the
upgraded/downgraded components.
7.2.6 Loading a project, including sources and additional data
Overview
As of SIMOTION V4.1 SP2, it is possible to load additional data (e.g. sources) to the target
device when saving a project to the CF card or downloading to the D4x5. This data is
required for:
Online object comparison (e.g. additional properties)
Various detailed comparisons (e.g. ST source file comparison)
Synchronization with online objects
In order to be able to load a project's sources and additional data to the PG, this must be
specified in the project under "Options" "Settings" "Download" "Store additional data
on the target device".
If the sources and additional data have been saved on the CF card, the option described in
the sections that follow becomes available.
Project comparison
You intend to carry out servicing work on a commissioned system and have brought a
project on your PC/PG. This project is not consistent with the project on the D4x5 in the
system. In order to analyze the differences, perform an object comparison via "Start object
comparison".
Commissioning (software)
7.2 Performing offline configuration for the D4x5
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 165
You have the following options in terms of re-establishing consistency:
In the object comparison, it is possible to establish consistency for sources and
technology objects on an object-granular basis.
Consistency can be established for the entire control unit by loading from the CF card via
"Target system" "Load" "Load CPU / drive unit to PG...".
Additional references
Detailed information on "loading data to the target device" can be found in the SIMOTION
SCOUT Basic Functions Function Manual.
7.2.7 Archiving a project to the CompactFlash Card (zip file)
Procedure
In SIMOTION SCOUT, you can save the project as a *.zip file to the CF card.
Proceed as follows to archive the SIMOTION project on the CF card:
1. Open SIMOTION SCOUT and select the "Project" > "Archive" menu command.
2. In the "Archive" dialog, select the SIMOTION project and save it to your drive (PG/PC).
3. Open the project.
4. Go online with the SIMOTION D4x5.
5. In the project navigator, select the SIMOTION D4x5 and select the "Target system"
"Load" "Save archive project on card..." menu command.
6. In the dialog that is displayed, select the project and click "Open". This saves the project
to the CF card as Project.zip in the directory USER\SIMOTION\HMI\PRJLOG.


Note
If you want to load the current project from the card, select the "Target system" "Copy
archived project from card to PG/PC..." menu command.
Prerequisite is that you have backed up the project with "Save archive project on card..."
each time a change was made.
Additional references
Detailed information on loading data to the target device can be found in the SIMOTION
SCOUT Basic Functions Function Manual.
Commissioning (software)
7.3 Performing online configuration for D4x5
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166 Commissioning and Hardware Installation Manual, 11/2010
7.3 Performing online configuration for D4x5
7.3.1 Overview
Introduction
You can configure the plant in online mode after having completed its wiring. You can load
the data of SINAMICS components connected via DRIVE-CLiQ to your PG/PC using the
"Automatic configuration" function. However, this is only possible for initial commissioning.

Note
Components without DRIVE-CLiQ connection must be edited in offline mode. You may need
to edit DRIVE-CLiQ components which were detected in the course of automatic
configuration (for example, adding encoder data if using SMC modules).

Requirements
Your system has been mounted and wired.
You have created a project in SIMOTION SCOUT and inserted a SIMOTION D4x5 in the
project.
You have configured the communication between the SIMOTION D4x5 and the PG/PC.
See Creating a project and configuring communication (Page 107).
Procedure
Online configuration involves the following steps:
Establishing an online connection (Page 167)
Starting the automatic configuration (Page 168)
Editing SINAMICS components (Page 172)
Downloading a project to SIMOTION D4x5 (Page 172)
Commissioning (software)
7.3 Performing online configuration for D4x5
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 167
7.3.2 Establish an online connection
Requirement
You have created a project.
Procedure
This section outlines the procedure for initial commissioning.
To perform online configuration, you must establish an online connection to the SIMOTION
D4x5. In this case, no connection can yet be established to the SINAMICS Integrated. An
appropriate message is output. Once the hardware configuration has been loaded to the
target device, an online connection to the SINAMICS Integrated is established automatically.
Proceed as follows:
1. Save and compile the project.
2. Establish an online connection.
3. Highlight the SIMOTION D4x5 device in the project navigator.
4. Use the "Download CPU / drive unit to target device" function to download the
SIMOTION D4x5 to the target device. The connection to the SINAMICS Integrated is
automatically established.
Result
Now you can perform the automatic configuration on the SINAMICS Integrated.
See Section Starting the automatic configuration (Page 168).
Additional references
Further information about establishing an online connection to the programming device/PC
can be found in the following documentation:
SIMOTION SCOUT Configuration Manual
SIMOTION SCOUT Online Help
SIMOTION Utilities & Applications FAQs
SIMOTION Utilities & Applications is part of the scope of delivery of SIMOTION SCOUT.
Commissioning (software)
7.3 Performing online configuration for D4x5
SIMOTION D4x5
168 Commissioning and Hardware Installation Manual, 11/2010
7.3.3 Starting the automatic configuration
Requirements
You have established the online connection to the SINAMICS Integrated.
Procedure
1. In the project navigator, open the "Automatic Configuration" dialog box by selecting
"SINAMICS Integrated" > "Automatic Configuration".


Figure 7-22 Starting the automatic configuration

2. Click the "Configure" button.
3. If the drive unit is not in the "Initial commissioning" state, the factory settings are restored
after acknowledging a prompt.
Commissioning (software)
7.3 Performing online configuration for D4x5
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 169
4. The drive object types can now be selected via a further dialog box.


Figure 7-23 Selecting the drive object type
5. Select whether a servo- or vector-type drive object is to be used.
6. Click "Create" to start the automatic configuration. As soon as automatic configuration
has been run through, an upload operation (Load to PG) is performed automatically.


Note
The components' firmware is upgraded or downgraded automatically based on the FW
version on the CF card and the FW version on the SINAMICS components (DRIVE-CLiQ
components, CBE30, PM340, etc.).
The upgrade can take several minutes and its progress is tracked by corresponding
messages appearing in the alarm window of SIMOTION SCOUT.
A firmware upgrade on DRIVE-CLiQ components is indicated by the RDY LED flashing
red and green:
FW update running: RDY LED flashes slowly (0.5 Hz)
FW update complete: RDY LED flashes quickly (2 Hz)
These flashing patterns are also displayed on the yellow RDY LED on the
SIMOTION D/CX32, and indicate that a FW update has been carried out on components
connected to the SIMOTION D/CX32 or that all components have completed the FW
update.
Go offline once all the FW updates have been completed. POWER ON the
upgraded/downgraded components.
Commissioning (software)
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170 Commissioning and Hardware Installation Manual, 11/2010
7. At the end of the automatic configuration, you are prompted whether you want to "Go
OFFLINE" or "Stay ONLINE" with the drive unit.


Figure 7-24 Automatic configuration completed
8. Execute the "Copy RAM to ROM ..." function on the D4x5 and the SINAMICS Integrated.
This saves the project on the CF card, meaning that it does not need to be reloaded after
switching off and on again.
Commissioning (software)
7.3 Performing online configuration for D4x5
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 171
Result
The DRIVE-CLiQ components loaded to the user project by means of automatic
configuration are displayed in the project navigator.

Figure 7-25 Project navigator with real configuration
You must then
If required, reconfigure SINAMICS components (e.g. components without a DRIVE-CLiQ
interface, such as an encoder connected via SMCxx).
Assign the "TO axis" to "Drive"
See also
Restoring the default settings of SINAMICS Integrated (Page 253)
Commissioning (software)
7.3 Performing online configuration for D4x5
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172 Commissioning and Hardware Installation Manual, 11/2010
7.3.4 Editing SINAMICS components
Requirement
You have loaded all connected DRIVE-CLiQ components to your user project.
You have shut down the connection to the target system (offline mode).
Procedure
You can now adapt your component to the application.
Run through the wizard for all the DRIVE-CLiQ components to be adapted and perform the
required reconfigurations.
This procedure conforms to the description Performing offline configuration for the D4x5
(Page 141).
The amount of editing work involved depends on the components used. For example, in the
case of a motor with a DRIVE-CLiQ interface, the motor and encoder type are identified
automatically.
7.3.5 Downloading a project to SIMOTION D4x5
After you have performed the reconfigurations, you must download the configuration to the
SIMOTION D4x5 (incl. SINAMICS Integrated).
1. Save and compile the project.
2. Go online.
Commissioning (software)
7.3 Performing online configuration for D4x5
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 173
3. To load the project, perform "Download project to target system".
The data must also be saved on the CF card to ensure that the project is retained in the
event of a power failure. The following options are available:
Perform the "Copy RAM to ROM..." function manually on the D4x5-and all drives
(SINAMICS Integrated, CX32, etc.).
In the "Download to Target System" dialog box, select the option "After loading, copy
RAM to ROM". You can change the default setting for this dialog box in "Options"
"Settings" "Download".



Figure 7-26 Download project to target system
The SIMOTION project is downloaded to the target system and the online connection to
the drives established automatically.


Note
Online access to the drives is not possible if HW Config is not loaded at the time you
initially connect to the target system.
Download HW Config first to enable online access to the drives.


Note
If you have deselected the "Drives" option under "Tools" > "Settings" > "Download" in
SIMOTION SCOUT, you must download the configuration separately to each drive
(SINAMICS Integrated, CX32, etc.).
To do this, select the drive (e.g. SINAMICS Integrated) in the project navigator and
perform "Download CPU / drive unit to target device".
For fast operation, we recommend that, in principle, the drives be deselected and a
download only performed when required.
4. To save the parameter calculations of the drive in the project, perform "Target device"
"Load CPU / drive unit to PG" for each drive.
The drive has been assigned parameters and commissioned. You can now test the drive via
the drive control panel.
Commissioning (software)
7.4 Configuring a CX32
SIMOTION D4x5
174 Commissioning and Hardware Installation Manual, 11/2010
See also
Optimizing drive and closed-loop controller (Page 238)
7.4 Configuring a CX32
7.4.1 Overview
The SIMOTION CX32 controller extension is a component in SINAMICS S120 booksize
format and supports scaling of the drive-end computing performance of the SIMOTION D435
and D445/D445-1 control units. Each CX32 can operate up to six additional servo, four
vector or eight V/f drives.
The CX32 controller extension offers the following advantages:
At only 25 mm wide, the CX32 is extremely compact.
Since the CX32 is connected to the SIMOTION D435/D445/D445-1 via DRIVE-CLiQ,
high-performance isochronous closed-loop control of the drives is possible without the
need for additional modules.
The communications interfaces on the SIMOTION D435/D445/D445-1 remain available
for other connections.
As the data for the CX32 is stored exclusively on the SIMOTION D435/D445/D445-1 CF
card, no action needs to be taken if the module is replaced.
The "Control operation" signal from an infeed connected to the SIMOTION D4x5 is
particularly easy to interconnect to the drives of a CX32.
SIMOTION CX32 is automatically also updated when the SIMOTION D4x5 is updated
7.4.2 Basic principles of the CX32
Basic principles of the CX32
Each CX32 is entered as a separate DRIVE object in the project navigator on the level of
SINAMICS Integrated. As a general principle, a CX32 can be configured the same way as
SINAMICS Integrated.
Communication
With CX32 (as with the SINAMICS Integrated) communication takes place via PROFIBUS
Integrated, although the SINAMICS Integrated is also used for routing to the relevant CX32
via DRIVE-CLiQ.
Commissioning (software)
7.4 Configuring a CX32
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 175
Communication with the CX32 runs in the same cycle (same DP cycle ) as communication
with the SINAMICS Integrated. Direct communication between two CX32 modules or the
SINAMICS Integrated and CX32 is not possible Exception: Interconnection of the infeed's
"Operation" signal for the CX32. Section Interconnecting the infeed "Operation" signal on the
CX32 (Page 185) describes how to interconnect the "Operation" signal.
Power-up
The CX32 does not require its own CF card. Both the firmware and parameterization are
stored centrally on the SIMOTION D CF card. This means that the CX32 modules only
power up after the SINAMICS Integrated has done so. As a result, it usually takes longer for
the system to power up than if a SIMOTION D were being used with just one SINAMICS
Integrated.
Copying from RAM to ROM also takes longer, as the devices perform this function one after
the other.
Please refer to Section CX32 configuring tools on how to detect if a power-up has been
completed during CX32 power-up (Page 184).
Online functions
Since the SINAMICS Integrated routes online functions to the CX32 via DRIVE-CLiQ,
operational performance is reduced by up to a factor of 2 in the case of online functions (e.g.
parameter modifications or downloads) compared to a similar installation with CU320.
Requirements for commissioning
In order to commission a SIMOTION D with CX32, all drive components which were
configured offline must also be present and connected to the correct DRIVE-CLiQ port.
Only when there are no topology errors
Will the download be successful (where a project created offline is loaded to the target
system)
Will the system startup be successful
Can the CX32 modules be accessed "online"
Loading the SINAMICS Integrated
If the SINAMICS Integrated of a SIMOTION D is loaded, the connected CX32 controller
extensions go offline as a result of reinitialization.
Commissioning (software)
7.4 Configuring a CX32
SIMOTION D4x5
176 Commissioning and Hardware Installation Manual, 11/2010
7.4.3 Preparing for configuration
Preparing for configuration
The following measures are required to enable online or offline configuration of a CX32.
1. Create a project and insert a SIMOTION D435 or D445/D445-1 (in this example, a D435
is used).
2. Double-click "D4x5" in the project navigator. The HW Config is displayed.
3. In the hardware catalog, open the "PROFIBUS DP" entry and select "SINAMICS".
4. Drag a SINAMICS CX32 to the PROFIBUS Integrated master system of the SIMOTION D
module. The mouse pointer permits the CX32 to be inserted on the master system only.
The "DP Slave Properties" screen form is displayed with the PROFIBUS address. The
PROFIBUS address is assigned automatically. See the table below.
Select the relevant DRIVE-CLiQ port by selecting the relevant PROFIBUS address (in
this example, PROFIBUS address 13).

Figure 7-27 Inserting CX32 in HW Config
Commissioning (software)
7.4 Configuring a CX32
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 177
5. Click "OK" to confirm your settings.
The CX32 is displayed in the project navigator and can be configured there in the same
way as a SINAMICS Integrated.
In HW Config, the respective PROFIBUS address of the CX32 is represented in
parentheses in the module icon.

Figure 7-28 CX32 in the project navigator
6. Save the project.
7. A CX32 is configured in the same way as a SINAMICS Integrated on a SIMOTION D4x5.
Using an offline configuration
Where configuration is being performed offline, configure the drive components (infeed,
motor modules, motor, encoder, terminal modules, etc.) by running through the drive wizard
for the SINAMICS Integrated or CX32. After you have done this, carry out commissioning.
Automatic commissioning
With automatic commissioning, the drive components that are physically connected to a
SIMOTION D are determined online. This means you only need a D4x5 project with the
CX32 modules configured in HW Config.
Commissioning (software)
7.4 Configuring a CX32
SIMOTION D4x5
178 Commissioning and Hardware Installation Manual, 11/2010
Assigning DRIVE-CLiQ ports to PROFIBUS addresses
Table 7- 3 CX32 PROFIBUS addresses (PROFIBUS Integrated)
DRIVE-CLiQ port PROFIBUS address (PROFIBUS Integrated)
X105 (D445/D445-1 only) 15
X104 (D445/D445-1 only) 14
X103 (D435/D445/D445-1) 13
X102 (D435/D445/D445-1) 12
X101 (D435/D445/D445-1) 11
X100 (D435/D445/D445-1) 10
See also
Configuring components (Page 143)
Performing CX32 configuration online (Page 183)
Performing CX32 configuration offline (Page 180)
Commissioning (software)
7.4 Configuring a CX32
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 179
7.4.4 Displaying the topology
Topology of the SINAMICS Integrated
Because the CX32 is connected to the SINAMICS Integrated of a SIMOTION D4x5 via
DRIVE-CLiQ, it is also represented in the topology tree of SINAMICS Integrated.
All inserted CX32s are represented in the SINAMICS Integrated topology without their
subtopology.

Figure 7-29 SINAMICS Integrated topology
Commissioning (software)
7.4 Configuring a CX32
SIMOTION D4x5
180 Commissioning and Hardware Installation Manual, 11/2010
CX32 topology
The CX32 topology represents the DRIVE-CLiQ port required for connection to the
SINAMICS Integrated. The drive objects connected to the CX32 are also displayed.

Figure 7-30 CX32 topology

Note
Topology errors may make it impossible to perform a download, power up a system, or
access a CX32 online.

See also
CX32 diagnostics (Page 187)
7.4.5 Performing CX32 configuration offline
Options
The following options are available for commissioning a project created offline:
Loading a project created offline to the target system
Loading a project created offline to the CF card
Commissioning (software)
7.4 Configuring a CX32
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 181
7.4.5.1 Loading a project created offline to the target system
Requirement
Your project, including all SINAMICS Integrated and CX32 drive components, must have
been configured already (see Preparing for configuration (Page 176)).
The actual topology must correspond with the reference topology.
Procedure
1. Deselect all target devices, with the exception of the SIMOTION D4x5, using the "Target
system" > "Select target devices" menu command in SCOUT.
2. Go online with the D4x5 by clicking "Connect to selected target devices".
3. Select the D4x5 in the project tree. Load the configuration to the SIMOTION D4x5 with
"Download CPU / drive unit to target device".
4. Copy the configuration from RAM to ROM with "Copy RAM to ROM".
5. Select "Connect target device" in the SINAMICS Integrated context menu. You will then
be connected to the SINAMICS Integrated online.
6. Load the parameterization by selecting "Target device" > "Download" in the SINAMICS
Integrated context menu.
7. Copy the parameterization from RAM to ROM with "Copy RAM to ROM".
8. Then select "Load CPU / drive unit to PG" to load the parameterization from the
SINAMICS Integrated back to the programming device in order to back up the SINAMICS
parameter calculations.
Result
The SINAMICS Integrated is now ready for operation (RDY LED is green). The CX32 can be
accessed online, although it will not yet have been configured (RDY LED is green, DP1 LED
is red).
1. Select "Connect Online" in the CX32 context menu. You will then be connected to the
CX32 online.
2. Load the parameterization to the CX32 and copy the parameterization from RAM to
ROM.
3. Then load the parameterization from the CX32 back to the programming device in order
to back up the SINAMICS parameter calculations.
4. Repeat steps 1 to 3 for each CX32.
5. Save the project.


Note
Topology errors may make it impossible to perform a download, power up a system, or
access a CX32 online.
Commissioning (software)
7.4 Configuring a CX32
SIMOTION D4x5
182 Commissioning and Hardware Installation Manual, 11/2010
See also
CX32 diagnostics (Page 187)
7.4.5.2 Loading a project created offline to the CF card
Loading a project created offline to the CF card has the advantage of being faster than a
download.
It should be noted, however, that the first system power-up will take longer, as the
SINAMICS Integrated and CX32 will perform one-off parameter calculations. These are
automatically backed up on the CF card.
Requirement
You will need a card reader for the SIMOTION D4x5 CF card.
Your project, including all SINAMICS Integrated and CX32 drive components, must have
been configured already (see Preparing for configuration (Page 176)).
The actual topology must correspond with the reference topology.
Procedure
1. Select "Load to file system" in the SIMOTION D4x5 context menu.
2. Select "Normal save" and click the "Select target" button. Select your card reader's drive
and confirm with "OK".
3. If a project has already been saved to the CF card, the message "Memory card file
already exists. Do you want overwrite this file?" appears. Confirm the message with
"Yes".
4. Once the project has been subsequently transferred to the CF card, insert the card into
the disconnected SIMOTION D4x5. Switch on the power supply for the D4x5 and
connected components.
5. After a successful power-up, the RDY LED of the D4x5 and CX32 will be green, as will
the DP1 LED of the CX32.
The components' firmware is automatically updated, depending on the FW version on the
SINAMICS components and on the CompactFlash Card. Please see the corresponding
instructions in the chapter titled Upgrading D4x5/CX32 (Page 188).

Note
Topology errors may make it impossible to perform a download, power up a system, or
access a CX32 online.

Commissioning (software)
7.4 Configuring a CX32
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 183
7.4.6 Performing CX32 configuration online
Requirement
You need a project which has already been created and which contains SIMOTION D4x5
with SINAMICS Integrated, as well as the CX32 controller extension(s).
Additional drive components (line module, motor modules, terminal modules, etc.) are
configured using "Automatic commissioning" and must not, therefore, be created offline.
Procedure
1. Deselect all target devices, with the exception of the SIMOTION D4x5, using the "Target
system" "Select target devices" menu command in SCOUT.
2. Go online with the D4x5 by clicking "Connect to selected target devices".
3. Select the D4x5 in the project tree. Load the configuration to the SIMOTION D4x5 with
"Download CPU / drive unit to target device".
4. Copy the configuration from RAM to ROM with "Target device" "Copy RAM to ROM".
5. Select "Connect target device" in the SINAMICS Integrated context menu. You will then
be connected to the SINAMICS Integrated online.
6. Perform "Automatic Configuration" on the SINAMICS Integrated. This may take several
minutes, depending on the number of components connected.
The SINAMICS Integrated is now ready for operation (RDY LED is green). The CX32 can
be accessed online, although it will not yet have been configured (RDY LED is green,
DP1 LED is red).
7. Select "Connect target device" in the CX32 context menu. You will then be connected to
the CX32 online.
8. Perform automatic configuration on the CX32. The CX32 is now also ready for operation
(RDY LED is green, DP1 LED is green).
9. Repeat steps 7 to 8 for each CX32.
10. Copy the parameterization from RAM to ROM with "Copy RAM to ROM".
11. Save the project.
If you run the "automatic configuration" in Step 6 and 8, a check will be made to see if the
firmware on the SINAMICS components differs from the firmware on the CF card. If it does,
you will be informed accordingly and the firmware on the SINAMICS components will be
upgraded/downgraded automatically.
The update can take several minutes and its progress is tracked by corresponding
messages appearing in the alarm window of SIMOTION SCOUT.
A firmware update on DRIVE-CLiQ components is indicated by the RDY LED flashing red
and green:
FW update running: RDY LED flashes slowly (0.5 Hz)
FW update complete: RDY LED flashes quickly (2 Hz)
Commissioning (software)
7.4 Configuring a CX32
SIMOTION D4x5
184 Commissioning and Hardware Installation Manual, 11/2010
These flashing patterns are also displayed on the yellow RDY LED on the
SIMOTION D/CX32, and indicate that a FW update has been carried out on components
connected to the SIMOTION D/CX32 or that all components have completed the FW update.
Go offline once all the FW updates have been completed.
POWER ON the upgraded/downgraded components.

Note
Topology errors may make it impossible to perform a download, power up a system, or
access a CX32 online.

See also
CX32 configuration instructions (Page 184)
CX32 diagnostics (Page 187)
7.4.7 CX32 configuration instructions
This section contains configuration tips relating to a number of features which are specific to
operating CX32 in conjunction with D4x5.
7.4.7.1 CX32 power-up
Powerup times
The CX32 does not require its own CF card. Both the firmware and parameterization are
stored centrally on the SIMOTION D CF card. This means the CX32 will only power up once
the SINAMICS Integrated has done so. As a result, it usually takes longer for the system to
power up compared to when a SIMOTION D is used with a SINAMICS Integrated and any
CU320 Control Units which may be connected.
Detecting when the CX32 powers up in the user program
The user must wait for the CX32 to power up before the drive objects can be accessed by
the user program.
One way of checking is to query the status of system variables on the CX32 drives.
<axis name>.actormonitoring.cyclicinterface = ACTIVE AND
<axis name>.sensordata[1].state = VALID
This procedure can also be used to establish when the SINAMICS Integrated drives power
up.
Commissioning (software)
7.4 Configuring a CX32
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 185
7.4.7.2 Interconnecting the infeed "Operation" signal on the CX32
Requirement
Drive line-up with SIMOTION D4x5 Control Unit and Line Module with DRIVE-CLiQ
interface
One or more CX32 Controller Extensions with no Line Module of their own (in other
words, the Motor Modules of the D4x5 and CX32 modules are supplied by the same DC
link).
In this example, the Line Module must to be connected to the SIMOTION D4x5 (not the
CX32).
Procedure
When drives are created in Drive System 1, the signal "Closed-loop control operation" r863.0
from the Line Module is automatically interconnected with the "Infeed operation" signal from
the drives (Drive 1...n) via p864.
There is an internal communication channel available (V4.1 SP1 and higher) for the CX32
Controller Extension (Drive System 2), via which the following signals from the SIMOTION
D4x5 Control Unit can be automatically interconnected to the CX32 Controller Extensions:
"Closed-loop control operation" from the Line Module connected to SIMOTION D4x5
Status of the SIMOTION D4x5 onboard digital inputs
These signals are available on the CX32 Controller Extension; since there is no need to
perform any additional configuration steps, it is very easy to make additional
interconnections with them within the CX32.
Commissioning (software)
7.4 Configuring a CX32
SIMOTION D4x5
186 Commissioning and Hardware Installation Manual, 11/2010
Interconnecting the infeed operation signal
The "Closed-loop control operation" signal from the Line Module connected to the
SIMOTION D4x5 is available in parameter r8510.0 of the CX32. Using the expert list or the
drive wizard, interconnect parameter p864 (drives on CX32) with parameter r8510.0 of the
CX32 Controller Extension.

Figure 7-31 Interconnecting the infeed operation signal

Figure 7-32 Operation signal interconnection (explanatory illustration)
Commissioning (software)
7.4 Configuring a CX32
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 187
Terminal status of D4x5 onboard digital inputs
The terminal statuses of the SIMOTION D4x5 onboard digital inputs are available in
parameter r8511[0..15] of the CX32. Additional interconnections can be made on the CX32
using these.
7.4.7.3 CX32 diagnostics
Error analysis/Error correction
In order to commission a SIMOTION D with CX32, all drive components which were
configured offline must also be present and connected to the correct DRIVE-CLiQ port.
Only when there are no topology errors
Will the download be successful (where a project created offline is loaded to the target
system)
Will the system startup be successful
Can the CX32 modules be accessed online
Error correction procedure
If the actual topology of the SINAMICS Integrated is either incomplete or has been inserted
incorrectly,
The RDY LED of the D4x5 remains yellow.
The RDY LED and DP1 LED on the CX32 are yellow and red respectively.
The CX32 cannot be accessed online in this state.
Procedure
Rectifying a topology error
1. Select "Target System" > "Select Target Devices" in SCOUT.
2. In the next window, deselect all the target devices apart from the D4x5 and the
SINAMICS Integrated.
3. Close the window by clicking "OK".
4. Now click the "Connect to selected target devices" button. The D4x5 and the SINAMICS
Integrated are connected.
5. Using the alarm window and the topology view of the SINAMICS Integrated, the topology
error can now be analyzed (for example, a component may be missing or in the wrong
port).
Commissioning (software)
7.4 Configuring a CX32
SIMOTION D4x5
188 Commissioning and Hardware Installation Manual, 11/2010
6. Switch off the D4x5 and the CX32, rectify the topology error, and switch all devices back
on again.
7. Once the SINAMICS Integrated has started up successfully, the RDY LED of the D4x5
will be green.
If the CX32 has been configured and has powered up successfully, the RDY LED and
DP1 LED of the CX32 will also be green.
If, however, the RDY LED on the CX32 is green but the DP1 LED is red, this means
the CX32 has not yet been configured. If this is the case, complete the next 4 steps.

On the CX32, the RDY LED is green but the DP1 LED is red:
In this state, the CX32 can be accessed online but has not been configured.
1. Select the CX32 and select "Connect Online" in the context menu.
2. Click the "Download CPU/drive unit to target device" button. This will load the CX32
configuration.
3. Save the data with "Copy RAM to ROM".
4. Once the SINAMICS Integrated and the CX32 have started up successfully, the RDY
LED of the D4x5 and the CX32 will be green, as will the DP1 LED of the CX32.
7.4.7.4 Upgrading D4x5/CX32
CX32 modules are always operated with the same firmware version as the SINAMICS
Integrated of a SIMOTION D.
This means no additional measures need to be taken for CX32 modules.
If the firmware version of the SIMOTION D is upgraded via HW Config, the SINAMICS
Integrated and the connected CX32-2 controller extension are also automatically upgraded
as of SCOUT V4.2.
If a SIMOTION SCOUT < V4.2 is used, the SINAMICS Integrated and CX32 must be
manually upgraded via the context menu "SINAMICS drive" "Target device" Device
version".
Commissioning (software)
7.4 Configuring a CX32
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 189
For instructions on upgrading a SIMOTION D see also Section Adapting a project (Updating
the project / Replacing the SIMOTION controller) (Page 272).

Note
The components' firmware is upgraded or downgraded automatically based on the FW
version on the CF card and the FW version on the SINAMICS components (DRIVE-CLiQ
components, CBE30, PM340, etc.).
The update can take several minutes and its progress is tracked by corresponding
messages appearing in the alarm window of SIMOTION SCOUT.
A firmware update on DRIVE-CLiQ components is indicated by the RDY LED flashing red
and green:
FW update running: RDY LED flashes slowly (0.5 Hz)
FW update complete: RDY LED flashes quickly (2 Hz)
These flashing patterns are also displayed on the yellow RDY LED on the
SIMOTION D/CX32, and indicate that a FW update has been carried out on components
connected to the SIMOTION D/CX32 or that all components have completed the FW update.
Go offline once all the FW updates have been completed. POWER ON the
upgraded/downgraded components.

7.4.7.5 Replacing D4x5/CX32
Replacing a module
When used as a replacement part, a CX32 behaves like other DRIVE-CLiQ components.
D445/D445-1 D435 replacement
Drag-and-drop can be used to carry out D445/D445-1 D435 module replacement in HW
Config.
Please note that it will not be possible to replace a D445/D445-1 with a D435 if a CX32 has
been configured with the address 14 or 15. (since a D435 does not have DRIVE-CLiQ ports
X104/X105, it does not have addresses 14 and 15).
Commissioning (software)
7.5 Additional information on configuring the SINAMICS Integrated
SIMOTION D4x5
190 Commissioning and Hardware Installation Manual, 11/2010
7.5 Additional information on configuring the SINAMICS Integrated
7.5.1 Settings for DP slave properties
Settings in HW Config
Depending on the cycle clock ratios (bus cycle clock, servo cycle clock) and the drives used,
it may be necessary to change the properties of the DP slave (SINAMICS Integrated) on the
PROFIBUS Integrated.
Open HW Config. Double-click the SINAMICS Integrated to display and, if necessary,
change the properties of the DP slave on the "Isochronous mode" tab. Example:
Synchronizing a drive to the isochronous DP cycle
SINAMICS Integrated and CX32 can only be operated isochronously. For this reason,
this option cannot be deactivated.
Changing the master application cycle (TMAPC)
The master application cycle must always be the same as the servo cycle clock set
(setting: "Context Menu of the D4x5" > "Set System Cycle Clocks" in the project tree).
Provided that the DP cycle is not scaled down to the position control cycle clock, the
master application cycle will always be the same as the DP cycle.
Changing the DP cycle (TDP)
Depending on the requirements in terms of the quantity structures and the response
times, the DP cycle may need to be changed (see also SIMOTION SCOUT Basic
Functions Function Manual).
In addition, the minimum DP cycle for vector drives also depends on the speed controller
clock cycle, which in turn depends on the drive quantity structure and the device type
used. This means that, particularly in the case of vector drives, the DP cycle must be
checked and changed if necessary (see Using vector drives (Page 191)).


Note
After TDP has been changed on the PROFIBUS master, the drive system must be
switched on (POWER ON).
Changing the TI and TO times
A change to TI/TO is required in the case of vector drives, for example, where the TI/TO
time depends on the number of vector drives or, with chassis devices, on the device type
used.
If you are changing settings for the SINAMICS Integrated, you must also change the settings
on the CX32 modules accordingly. This is easily done by using the Align button to transfer
the settings for all the CX32 modules.
Commissioning (software)
7.5 Additional information on configuring the SINAMICS Integrated
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 191

Figure 7-33 HW Config - settings
The times are modified by changing the value in the "Factor" field.
Additional references
For additional information, please refer to the
SINAMICS S120 Function Manual
SIMOTION SCOUT Basic Functions Function Manual
7.5.2 Using vector drives
Changes need to be made in HW Config when using SINAMICS vector drives. This means,
for example, that the TI/TO time and the minimum DP cycle depend on the number of vector
drives or, with chassis drives, also on the device type used.
Commissioning (software)
7.5 Additional information on configuring the SINAMICS Integrated
SIMOTION D4x5
192 Commissioning and Hardware Installation Manual, 11/2010
Therefore, we recommend adopting the following procedure is when using vector drives with
SIMOTION D4x5.
Scenario 1: Current and speed controller cycle is known
As long as you know the current and speed controller cycle, you will be able to determine
times TMAPC, TDP, TI, and TO . Where there are several drives with different cycle clocks, the
largest cycle clock must be used for the current and speed controller cycle.
Procedure
1. Open HW Config. Double-clicking SINAMICS Integrated allows you to change the
properties of the DP slave on the "Isochronous mode" tab.
2. For TI = TO =, enter an integer multiple of the current controller cycle.
3. For TDP, enter an integer multiple of the speed controller cycle. For drives on the
SINAMICS Integrated, TDP must always be TO.
4. Enter TMAPC = TDP (exception: You are working with cycle clock scaling; i.e. position
control cycle clock > DP cycle).
5. Use the "Download project to target system" menu command to load the configuration to
the SIMOTION D4x5.
6. After the download has successfully completed, you should determine the current and
speed controller cycles of the drives from the drives' expert lists, as the cycle clocks are
set in the SINAMICS drive unit after a project has been downloaded.
p115[0]: Current controller cycle
p115[1]: Speed controller cycle
7. If the current and speed controller cycles from the expert lists are different to the cycle
clocks used in steps 2 and 3, you will have to repeat the steps with the current values for
the current and speed controller cycles.
Table 7- 4 Example for power units in booksize format (vector drives)
Example Settings
1 or 2 vector drives
Current controller cycle = 250 s
Speed controller cycle = 1 ms
TI = TO = at least 250 s
TDP = 1 ms (... or 2 ms, 3 ms, etc.)
TMAPC = TDP
3 or 4 vector drives
Current controller cycle = 500 s
Speed controller cycle = 2 ms
TI = TO = at least 500 s
TDP = 2 ms (... or 4 ms, 8 ms, etc.)
TMAPC = TDP


Note
Vector drives in chassis format can also be operated with a current controller sampling time
of 400 s, amongst other settings.

Commissioning (software)
7.5 Additional information on configuring the SINAMICS Integrated
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 193
In a SIMOTION context, the following should be considered:
A current controller sampling time of 400 s is only possible if control is via a
SINAMICS S120 control unit, which is not operated isochronously via
PROFIBUS/PROFINET on SIMOTION D.
If the bus is operated isochronously, only cycle clocks with an integer multiple of 125 s
are possible (375 s or 500 s instead of 400 s, for example).
The PROFIBUS Integrated of a D4x5/CX32 is always isochronous! This means a current
controller sampling time of 400 s is not possible.
With CU parameter p0092 = 1, the sampling times are pre-assigned so that isochronous
operation with a controller is possible.
Scenario 2: Current and speed controller cycle is not known
This procedure is especially suitable for devices in chassis format, as the current and speed
controller cycle also depends on the relevant device type.
1. To determine which cycle clocks are set in the SINAMICS drive unit after a project has
been downloaded, first set reliable values for the cycle clocks in HW Config (see table
"Recommended cycle clock settings in HW Config").
2. Use the "Download project to target system" menu command to download the
parameterization.
3. After the download has successfully completed, you will be able to determine all the
current and speed controller clock cycles of the drives from the drives' expert lists.
p115[0]: Current controller cycle
p115[1]: Speed controller cycle
4. If required, it is now possible to optimize the TMAPC, TDP, TI and TO times in HW Config
(see procedure for Scenario 1).
Table 7- 5 Recommended cycle clock settings in HW Config
Setting Explanation
TDP = 3.0 ms TDP = DP cycle time
TI = TO = 1.5 ms TI = time of actual value acquisition
TO = time of setpoint transfer
TMAPC = 3.0 ms TMAPC = master application cycle time
Output cams / measuring inputs with vector drives
With vector drives, the cycle clock ratios (current controller cycle clock, speed controller
cycle clock, sampling time of the inputs/outputs, etc.) depend on the number of vector drives,
or with chassis units also on the device type used.
Note the information in Section Current controller cycle clocks <> 125 s / Using output
cams and measuring inputs (Page 199).
Commissioning (software)
7.5 Additional information on configuring the SINAMICS Integrated
SIMOTION D4x5
194 Commissioning and Hardware Installation Manual, 11/2010
Additional references
Additional information on quantity structures and cycle clock settings can be found in the
SINAMICS S120 Function Manual.
See also
Settings for DP slave properties (Page 190)
7.5.3 Setting the time of day
Time on SIMOTION (real-time clock)
SIMOTION D4x5 has an integrated real-time clock. All events on a module (alarms,
messages, etc.) are "time-stamped" based on the time shown by this real-time clock.
To set the clock from SIMOTION SCOUT, select the D4x5 in the project tree, followed by
"Target system" "Set time".
Alternatively, the clock can be set using the "rtc" system function block.
SINAMICS system runtime (operating hours meter)
With the SINAMICS Integrated of a SIMOTION D, controller extensions and the
SINAMICS S110/S120 control units, faults and alarms are "time-stamped" on the basis of
the system runtime. This means that events are recorded by default on the basis of
operating hours rather than a particular time of day or date.
System runtime
The entire system runtime is displayed in CU parameter p2114.
p2114[0] indicates the system runtime in milliseconds. After reaching 86,400,000 ms (24
hours), the value is reset.
p2114[1] indicates the system runtime in days.
At power-off the counter value is saved. After the drive unit is powered-up, the counter
continues to run with the value that was saved the last time that the drive unit was powered-
down.
As a result, the drive displays the system runtime from 00:00:00 on 01/01/1992 in both the
alarm window in SIMOTION SCOUT and the diagnostic buffer for entries.
If faults and warnings need to be "time-stamped" based on a time of day, "Time-stamp
operating hours" needs to be changed to "Time-stamp UTC format" as described below.
Requirements
A message frame 39x is required for the time synchronization. If the automatic PROFIdrive
message frame setting is selected for the control unit, this message frame is used
automatically.
Commissioning (software)
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(See Section Calling the drive wizard (Page 142), Standard/automatic setting)
If the message frames are specified manually, message frame 39x must be set up. See
Section Message frame configuration (Page 216).
So that drive units can be synchronized with the SIMOTION time, they must support
message frame 39x and the UTC time format.
These include, for example:
SINAMICS Integrated of the SIMOTION D
CX32/CX32-2 controller extensions
SINAMICS S110/S120 CU305, CU310, CU320, CU320-2 control units connected via
PROFIBUS or PROFINET
Synchronizing the SINAMICS clock
Proceed as follows to convert the SINAMICS clock to UTC format and to synchronize this
with the SIMOTION clock:
1. Call the D4x5 context menu in the project navigator.
2. Select the "Properties" entry in the context menu.
3. Select the "Perform time synchronization with SINAMICS drive units" option in the
"Settings" tab of the "Properties - D4x5" dialog box.


Note
This setting is automatically activated for new projects as of V4.2 and applies for all drive
units connected to the D4x5. The SINAMICS clock is automatically synchronized with the
SIMOTION clock for all drive units with configured message frame 39x.
The first time synchronization is performed after the SIMOTION D control unit has reached
the RUN mode.
To compensate for deviations between the SIMOTION and SINAMICS clocks, the time of
day is automatically resynchronized at regular intervals.
Via the system variable _driveStates.allClocksSynchronized on the device, the user program
can query whether the automatic time synchronization is activated (=YES) or deactivated
(=NO).
Before the first synchronization, alarms and messages are stored with the time stamp valid
in the SINAMICS at this time, all subsequent alarms and messages with the synchronized
time.
The first time synchronization after switching on is entered with the status of the operating
hours counter and the time (UTC time, synchronized with SIMOTION) in the diagnostic
buffer of the drive (e.g. SINAMICS Integrated).
Commissioning (software)
7.5 Additional information on configuring the SINAMICS Integrated
SIMOTION D4x5
196 Commissioning and Hardware Installation Manual, 11/2010

Figure 7-34 Diagnostics buffer entry, time synchronization

Note
The time synchronization must be performed "applicatively" for SIMOTION versions < V4.2.
You can find a sample program in the SIMOTION Utilities & Applications.
If the "applicative time synchronization" is used for SIMOTION versions V4.2, the time
synchronization must be deactivated via the "Settings on the Device" dialog box.
SIMOTION Utilities & Applications is part of the scope of delivery of SIMOTION SCOUT.

Compensation of runtime deviations
To compensate for deviations between the SIMOTION and SINAMICS clocks, the time of
day is automatically resynchronized at regular intervals.
The following behavior must be taken into consideration when setting the SIMOTION time:
"Time/date to be set" is after "Time/date on SINAMICS": Time and date on SINAMICS is
updated.
"Time/date to be set" is before "Time/date on SINAMICS": The SINAMICS clock must be
stopped until the SINAMICS "Time/date" has caught up with "Time/date to be set".
Adopting this procedure ensures that the sequence of SINAMICS diagnostic buffer entries
remains the same, even when the runtime differences are aligned.
The SINAMICS clock operates with a resolution of 1 ms. A synchronization accuracy of 1 ms
can be achieved for all bus cycle clocks that can be divided exactly by 1 ms (e.g. 1 ms, 2 ms,
3 ms, etc.).
A slightly lower synchronization accuracy is achieved for all bus cycle clocks that cannot be
divided exactly by 1 ms (e.g. 1.25 ms) due to the system.
Commissioning (software)
7.5 Additional information on configuring the SINAMICS Integrated
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7.5.4 SINAMICS diagnostic buffer
Requirement
The diagnostic buffer is supported for SINAMICS S120 devices as of version V2.6. The
SINAMICS Integrated variants support the diagnostic buffer as of version V2.5. There are
minimum requirements for the HW version for the following components:
- For D425/D435, product version "D",
- For CU320 (-0AA1), product version "C".
Procedure
To do this, select the SINAMICS Integrated, the CX32 or the SINAMICS S120 control unit in
the project tree. Then select "Target System" > "Device Diagnostics" in the menu.
In addition, the SINAMICS diagnostic buffer entries are displayed in the D4x5 device
diagnostics. All D4x5 diagnostics buffer entries are displayed first, followed by those for the
SINAMICS Integrated and the CX32. The start of the SINAMICS diagnostics buffer entries is
identified by the following entry:
>>>>>> >>>>>> Start of SINAMICS Integrated diagnostics buffer, station address = x
<<<<<<
You also have the option of viewing the SIMOTION D4x5 and SINAMICS Integrated
diagnostics buffers via IT DIAG.
7.5.5 Acyclic communication with the drive
Overview
PROFIdrive drive units are supplied with control signals and setpoints by the controller and
return status signals and actual values. These signals are normally transferred cyclically (i.e.
continuously) between the controller and the drive.
For the SINAMICS S110/S120, configure the axis message frames for data exchange (see
Performing the configuration for the D4x5 offline (Page 141)).
As well as offering cyclic data exchange, PROFIdrive drive units have an acyclic
communication channel. In particular, this is used for reading and writing drive parameters
(e.g. error codes, warnings, controller parameters, motor data, etc.).
As a result, data can be transferred on an "acyclic" as opposed to a "cyclic" basis when
required. Acyclic reading and writing of parameters for PROFIdrive drives is based on the
DP V1 services "Read data set" and "Write data set".
The acyclic DP V1 services are transferred in parallel to the cyclic communication via
PROFIBUS or PROFINET. The PROFIdrive profile specifies precisely how these basic
mechanisms are used for read/write access to parameters of a PROFIdrive-compliant drive.
The PROFIdrive standard states that "pipelining" of jobs on PROFIdrive drives is not
supported. This means:
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198 Commissioning and Hardware Installation Manual, 11/2010
Only one "Write/read data set" can be performed at any one time on a drive unit (e.g.
SINAMICS S110/S120 control unit or the SINAMICS Integrated of a SIMOTION D).
However, if several PROFIdrive drive units are connected to a controller, a job can be
processed for each of these drive units at the same time. In this case, the maximum total
number of jobs will depend on the control (for SIMOTION, this is a maximum of eight jobs
at a time).
For acyclic data exchange with SINAMICS drives, this means you will have to coordinate the
write/read jobs with each other (buffer managemenr). An interlock must be set to prevent the
application or different parts of the application from sending overlapping jobs to the same
PROFIdrive drive unit.
Additional references
Additional information on how to use DP V1 services can be found in the SIMOTION
Communication System Manual.
SIMOTION Utilities & Applications also has a DP-V1 library with functions that are capable of
performing coordination tasks commonly associated with acyclic communication. The library
not only coordinates access to the system functions
(_ReadRecord/_WriteRecord/_readDriveParameter/_writeDriveParameter/, etc.), but also
expands the range of functions for frequently required tasks, e.g. the reading of faults and
alarms from the drive unit.
SIMOTION Utilities & Applications is part of the scope of delivery of SIMOTION SCOUT.
The following functions are available in the DP V1 library:
Buffer management (coordination of a number of parallel DP V1 services)
StartUp (function for coordinating the power-up of the SINAMICS drive with SIMOTION)
TimeSync (applicative time synchronization: Transfer of SIMOTION time of day to the
SINAMICS drives)
SetActIn (activating/deactivating objects in SIMOTION and SINAMICS)
RwnPar (reading and writing of drive parameters)
GetFault (reading of faults and alarms from the drive)
7.5.6 Control properties and performance features
With a few exceptions, the integrated drive control of SIMOTION D4x5 and CX32 has the
same control properties and performance features as the SINAMICS S120 CU320 control
unit.
However, the following points must be particularly observed:
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7.5 Additional information on configuring the SINAMICS Integrated
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SINAMICS Integrated and CX32 have no basic positioner (EPOS). The EPOS
functionality is provided by the SIMOTION technology functions.
The BOP20 Basic Operator Panel cannot be connected to the SIMOTION D4x5.
The following alternative options are available:
Use of SIMATIC HMI devices (e.g. TP177B, configurable with WinCC flexible)
Use of SIMOTION IT DIAG: You can use a Web browser to access the standard
diagnostics pages of the SIMOTION D4x5 (diagnostics and alarm buffers, Watch
table, read/write SIMOTION variables and drive parameters, access protection, trace
function, etc.)
You also have the option of creating your own Web pages, in order for example to
visualize machine states and implement service functions. The SIMOTION D4x5 Web
pages can be accessed for example using a PC or PDA over Ethernet. Wireless
access is also possible in conjunction with WLAN.
The use of the CU parameter p972 is restricted with SIMOTION D4x5. CU parameter
p972 can be used to reset the drive unit. You can use this method, for example, in the
context of the implementation of modular machine concepts to force a restart of the CX32
controller extension (see the description of functions titled Motion Control Basic Functions
for Modular Machines).
NOTICE

You are not permitted to use parameter p972 on the SIMOTION D4x5 to reset the drive.
This leads to a fault on the SIMOTION D4x5, with all eight status LEDs flickering red. In
this fault situation, the SIMOTION D4x5 must be switched off and back on again.
7.5.7 Current controller cycle clocks <> 125 s / use of output cams and measuring
inputs
If current controller cycle clocks <> 125 s are used, the parameter calculations of the drive
must be transferred to the PG when using cam outputs on the TM15 / TM17 High Feature or
for global measuring inputs, and FastIO configuration generated again.
A change of the current controller cycle clock may have effects on the sampling times of the
inputs/outputs on the drive side (e.g. TM15/TM17 High Feature, p4099 Sampling time of the
inputs/outputs).
Sampling times <> 125 s occur in the following cases:
For servo drives with manual change of the current controller sampling time (drive
parameters p112 and p115[0])
For vector drives depending on the number of vector drives and with chassis units
depending on the device type used
If only an infeed and no drives are connected to the drive unit, then the sampling time is
250 s
For the cam outputs and the measuring input inputs (only for global measuring inputs) to
function correctly, the sampling times must be known to the engineering system.
Commissioning (software)
7.6 Testing a drive with the drive control panel
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200 Commissioning and Hardware Installation Manual, 11/2010
Table 7- 6 Influence of the current controller cycle clock on the dead time compensation
Current controller cycle clock has no
effect on the function
Current controller cycle clock has an
effect on the function
Cam outputs SIMOTION D TM15/TM17 High Feature
Measuring input inputs
(global measuring
inputs)
D4x5-2 (terminal X142)
TM15/TM17 High Feature
SIMOTION D (except D4x5-2,
terminal X142)
Controller extension (CX)
SINAMICS S110/S120 control
units
Measuring input inputs
(local measuring
inputs)
--- ---
In order that the changed cycle clock ratios are taken into account by the the engineering
system, proceed as follows:
1. Go online and perform a project download. The SINAMICS performs parameter
calculations once. These are automatically backed up on the CF card.
2. Perform an upload to the PG ("Target system" > Load" > "Load CPU / drive unit to PG").
3. This transfers the parameter calculations of the drive to the PG. The cycle clock ratios are
then known in the engineering system.
4. Go offline.
5. Generate the configuration information (Fast IO configuration) again. To do this, select
the SIMOTION CPU in the project tree and right-click to open the context menu "Fast IO"
> "Create new configuration".
6. Click "Save project and compile all".
7. Go online and download the project to the target system.
SCOUT uses the described procedure to calculate internal system data that is required for
outputting/detecting signals with a high level of position accuracy.

Note
If the cycle clock ratios are not set correctly, an appropriate message is output in the
diagnostic buffer.

7.6 Testing a drive with the drive control panel
Introduction
You can test a configured drive with the drive control panel, where you can specify a speed
and adjust it with a scaling factor. The drive control panel should only be used for
commissioning purposes.
Commissioning (software)
7.6 Testing a drive with the drive control panel
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Commissioning and Hardware Installation Manual, 11/2010 201
Requirements
The project has been downloaded to the target system.
SIMOTION SCOUT is in online mode.
The drive is not being used by a current project in RUN mode.
WARNING

Make sure no one is endangered by the drive test.
Testing a drive with the drive control panel
1. Change to the configured drive in the Project Navigator and open the drive control panel
by selecting "Commissioning" > "Control panel". The drive control panel opens in the
detail view.

Figure 7-35 Drive control panel

2. To display the control range and axis diagnostics, click the "Show/hide control range" and
"Show/hide diagnostics area" buttons.
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3. Click "Assume control priority". The "Assume Control Priority" dialog box is opened.


Note
If you are using an infeed without a DRIVE-CLiQ interface, you will have to interconnect
the "Infeed operation" signal (drive parameter p864) yourself. If you are using an infeed
with a DRIVE-CLiQ interface, select the infeed for which the control priority is to be
assumed under "Infeed" in the "Assume Control Priority" dialog box.
If the infeed signal "Closed-loop control operation" already has a BICO interconnection to
the drive, the infeed is permanently specified (infeed selection and checkbox are grayed
out).
The infeed must be switched on before the drive can move ("LM" button, switch infeed
on/off).

Figure 7-36 Assuming control priority

4. Read the notices and click "Accept" to confirm.
5. Select the "Enables" checkbox to enable the drive.
All enables are now set except ON/OFF1.
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6. Enter the desired setpoint in the entry field, and, as a safety setting, slide the scaling to
0%.

Figure 7-37 Entering a setpoint
7. Click the "Drive On" button. The green "Enable available" LED lights up. If you move the
slider to the right, the drive rotates. The current motor speed is displayed under "Actual".
8. Click "Drive Off" to stop the drive after the test.
9. Deactivate the enable and click the "Give up control priority" button to deactivate control
from the PG/PC. In this state, you can no longer make the drive rotate.
7.7 Creating and testing axes
7.7.1 Overview of SIMOTION engineering
Performing engineering with SIMOTION SCOUT
You use the engineering software to configure the individual axes and define the project
sequence by means of programs.
1. First, run through the axis wizard to configure the axes and interconnect to the real drive
(e.g. SINAMICS Integrated).
2. Then, select the "SINAMICS_Integrated" in the project navigator and deactivate the
"Connect Online" option in the context menu. This only downloads the project to the
SIMOTION D4x5.
Provided you have completed configuration at the drive end, we strongly recommend you
deactivate the SINAMICS Integrated so that work can be carried out faster via "Target
system" > "Select target device".
3. Complete your SIMOTION application, for example, by creating axis functions and
SIMOTION execution programs.
4. Compile the project and download it to the SIMOTION D4x5.
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7.7 Creating and testing axes
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204 Commissioning and Hardware Installation Manual, 11/2010
See also
Downloading a project into the target system (Page 161)
Downloading a project to the CF card (Page 163)
7.7.2 Creating an axis with the axis wizard
Overview
The TO axis provides the user with the technological functionality and the interface to the
drive/actuator. The TO axis processes the motion control commands from the user program
(e.g. MCC) and coordinates the interface to the drives. It executes control and motion
commands and indicates statuses and actual values. The TO axis communicates with an
actuator (drive or hydraulic valve) via a field bus system (PROFIBUS or PROFINET via
PROFIdrive protocol) or via a direct setpoint interface (analog 10 V or pulse/direction).
When running through the axis wizard, the basic settings are made for the axis and the
TO axis interconnected to a drive (e.g. SINAMICS Integrated). Further options are available
when "Symbolic assignment and adaptation" is used:
A real axis is interconnected to an already configured drive
A real axis including drive is created via the axis wizard and the drive interconnected to
the axis
A real axis is created without assigning this to a drive (assignment is made later)
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Inserting an axis
1. In the project navigator, double-click the entry "Axis" > "Insert Axis".
This will access the axis wizard. Set the required technology and then click "OK".

Figure 7-38 Inserting an axis
2. Set an axis type and, if required, configure the units.
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Figure 7-39 Defining the axis type
3. Create a new drive or make the assignment to an existing drive.
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Commissioning and Hardware Installation Manual, 11/2010 207

Figure 7-40 Assigning a drive
The following setting options are available for the drive assignment:
Assign drive
Assigning a previously configured drive
Assign later
The TO axis is to be assigned to a drive at a later point in time.
This enables
The PLC and motion control functions to be completely configured by a programmer
even without drive know-how using technology objects (e.g. TO axis) and loaded to
the device
The drives to be separately configured and optimized by a drive expert and
The technology objects to be symbolically assigned later to the drive objects via an
interconnection dialog box
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Create drive
From the assignment dialog box, a new drive can be created on an existing drive unit
(e.g. S120 CU320-2 or SINAMICS Integrated) and assigned to the axis. This allows the
axis, including the drive, to be created in one operation. It is not necessary to configure a
drive before creating an axis.
Set up addresses
The addresses must be set up manually if "Symbolic assignment and adaptation" is not
used. This corresponds to the previous methods of the drive and axis configuration,
available in SCOUT versions < V4.2.
This is required, for example, for drive units that do not support symbolic assignment (e.g.
SINAMICS S120 with FW version < 2.6.2, MASTERDRIVES, SIMODRIVE, etc.)
The address list in the "All Addresses" view provides an overview of the assignments to all
interfaces of the TO axis. From this view, the assignments can also be changed via the
interconnection dialog box ( button).

Note
The methods of the drive and axis configuration, previously available in SCOUT versions
< V4.2, are still available. The symbolic assignment must be deactivated for these methods.

4. Run through the wizard and enter the settings of your system. The required axis message
frames as well as the addresses used are automatically specified by the engineering
system. Message frames are also extended and interconnections created automatically in
the drive depending on the selected TO technology (e.g. SINAMICS Safety Integrated)
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5. Click Finish to confirm the "Summary" window.
The configured real axis is displayed in the project navigator.

Figure 7-41 Axis wizard summary


Note
During system power-up, reference variables as well as drive and encoder data of the
SINAMICS are automatically taken over for the SIMOTION configuration data of the
SIMOTION technology objects "TO axis" and "TO externalEncoder".
Encoder assignment
With a position axis, encoder 1 is also created at the Axis TO (motor encoder) and
automatically assigned to the first encoder on the drive.
If encoder 2 (direct encoder) is created at the TO axis, it is assigned to the second encoder
of the drive control.
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Result
The configured axis will appear in the project navigator.
Save and compile the project and download it to the target system.
On completion of the axis wizard, the symbolic drive assignment is visible:
Via the "configuration" of the axis
Via the address list (view all addresses)

The assignment dialog box can be called again from these dialog boxes using the " "
button.
Instead of calling the assignment dialog, it is also possible to edit the input field
containing the symbolic name directly.
Safety data block (SIDB) and technology data block (TDB)
The activation of
The technology data block (for the cyclic exchange of technology data, e.g. actual torque
value) and
The safety data block (to support the SINAMICS Safety Integrated extended functions by
the TO)
can be made in the Configuration of the TO Axis dialog box. ("Change ..." button under
functions).
The assignment is always made to the drive DO of the actuator of the axis. The system
automatically generates a message frame extension and the BICO interconnection of the
relevant SINAMICS parameters.

Note
The safety data block (SIDB) is automatically configured by the engineering system and
interconnected in the drive.
The PROFIsafe message frame must be configured by the user.

If the activation of the safety functions is to be made using PROFIsafe, configure the
PROFIsafe communication to the higher-level SIMATIC F-CPU (see SINAMICS S120 Safety
Integrated Function Manual).
I/O signals at the TO axis
For the assignment of I/O signals on the TO axis (e.g. the inputs for the homing output cam
or hardware limit switches), call the assignment dialog box from the parameterization dialog
boxes of the created TOs or from the address list (view of all addresses) by clicking the
button.
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See also
See Section Downloading a project to the target system (Page 161). For further information
about the symbolic assignment, see the
SCOUTBasic Functions Function Manual.
7.7.3 Testing the axis with the axis control panel
Axis control panel
The axis control panel is used exclusively for testing axes. You can use the axis control
panel for the following tasks, for example:
To test each part of the system individually before program-driven axis motions are
initiated.
In the event of an error, to test whether the individual axes and drives can be traversed
from the axis control panel
To traverse the axes for optimization purposes (controller optimization)
To perform active homing
To set and remove the axis enable
To test an axis that has been created
Requirement
The following requirements must be fulfilled for testing:
The project has been downloaded to the target system.
SIMOTION SCOUT is in online mode.
The mode switch is in position STOPU.
Recommendation: Operate the mode selector only via SIMOTION SCOUT ("Target system"
> "Control operating mode").
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Axis test
1. Open the AXES folder in the project navigator and click the "Control Panel" entry below
the axis (for example, Axis_1).
The axis control panel is displayed.

Figure 7-42 Axis control panel

2. To display the control range and axis diagnostics, click the "Show/hide control range" and
"Show/hide diagnostics area" buttons.
3. Click "Assume control priority".
If the CPU is in RUN mode, confirm the prompt that appears with "Yes" to set the control
to STOPU mode.


Note
In order to move the axis from the PG/PC, you must assume control priority. However, by
pressing the SPACER bar, you can stop the axis at any time.
If you are using the axis control panel for a real axis, you must first activate the infeed for
SINAMICS drives before the axis can be moved. The infeed must be activated before you
enable the axis.
4. The "Assume Control Priority" dialog box is opened.
Read the notices and click "Accept" to confirm. The activated Service function is
displayed via the LEDs (RUN flashes green at 2 Hz and SU/PF flashes yellow at 2 Hz)
5. To enable the axis, click the "Set/remove enable" button.
Confirm the "Switch Axis Enable" dialog with with "OK".


Note
If you are using an infeed without a DRIVE-CLiQ interface, you will have to interconnect
the "Infeed operation" signal (drive parameter p864) yourself.
If you are using an infeed with a DRIVE-CLiQ interface, select the infeed for which the
control priority is to be assumed under "Infeed" in the "Switch Axis Enable" dialog box.
Select this checkbox when the control priority is to be fetched and activated. If the infeed
signal "Closed-loop control operation" already has a BICO interconnection to the drive,
the infeed is permanently specified (infeed selection and checkbox are grayed out).

Commissioning (software)
7.8 Activating the infeed (line module)
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 213
6. To traverse the axis, click the "Position-controlled traversing of the axis" button.
7. Enter a velocity and close the dialog box by clicking "OK".
8. Click the "Start motion" button to traverse the axis. You can monitor the traversing motion
under speed and position. Use "Stop motion" to stop axis movement again.
9. To cancel the enable and switch off the infeed, click the "Set/remove enable" button.
Confirm the "Remove Axis Enable" dialog with with "OK".
10. Click the "Give up control priority" button to deactivate axis control from the PG/PC. In
this operating mode, the axes can no longer be controlled from the PG/PC.
See also
Activating the infeed (line module) (Page 213)
7.8 Activating the infeed (line module)
Requirement
Before a drive can be traversed, the infeed (line module) must be switched on and the
"Closed-loop control operation" signal of the infeed must be present at the drives.
If this is not taken into account, this can result in a fault state, and in the worst case, damage
to the infeed.
How the infeed is controlled and how the drives receive the Ready signal depends on the
type of infeed used.
A distinction is made between:
Infeeds without DRIVE-CLiQ connection
Infeeds with DRIVE-CLiQ connection
Commissioning (software)
7.8 Activating the infeed (line module)
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214 Commissioning and Hardware Installation Manual, 11/2010
7.8.1 Infeed without DRIVE-CLiQ connection
The infeed is controlled via terminals on the line module, e.g. DO Ready (DC link is
precharged and pulse enable is set).
These terminals must be connected to the SIMOTION D4x5 (e.g. wire "DO Ready of the
infeed" to "X122, DI 0 of the D4x5").
The enable signal is queried when the drive is configured and must be interconnected
accordingly.

Figure 7-43 Interconnection of the "Infeed in operation" signal
7.8.2 Infeeds with DRIVE-CLiQ connection
The infeed is controlled via DRIVE-CLiQ. The infeed is switched on or off by the
SIMOTION D4x5 via PROFIdrive message frame 370.
If "Symbolic assignments and adaptation" is used, message frame 370 is set automatically
when setting standard/automatic (see Section Calling the drive wizard (Page 142)).
Commissioning (software)
7.8 Activating the infeed (line module)
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 215
With message frame 370, the required BICO interconnections to the message frame are
created automatically on the drive unit.
If an infeed with DRIVE-CLiQ connection has already been created, the infeed signal
"Closed-loop control operation, r863.0" is automatically interconnected to "Infeed
operation, p864" of the drive when drives are inserted (only applies to drives that are
attached to the same drive unit as the infeed).
The FB _LineModule_control function block is available on the controller for control and
diagnostics of the infeed.

Note
Always create the infeed first so that the infeed "Closed-loop control operation" signal is
automatically interconnected to a drive when this is inserted.
Recommendation: If the drive unit has not been configured, use "Configure drive unit" in the
project navigator. "Configure drive unit" has the advantage that all basic settings for the drive
unit are queried via one wizard.

FB _LineModule_control
The _LineModule_control function block (FB) can be used to switch the infeed on and off and
also perform simple diagnostics.
The following infeeds are supported by the _LineModule_control function block:
Basic line modules (BLM)
Smart line modules (SLM)
Active line modules (ALM)
The _LineModule_control FB is part of the command library of the "SIMOTION SCOUT"
engineering system. You can find the FB at "Drives" "SINAMICS".
For detailed information on the _LineModule_control FB, refer to the SIMOTION SCOUT
online help or the Standard Function for SINAMICS S120 Line Modules Function Manual.
CX32
Further information on how to use line modules with the CX32 can be found in Section
Interconnecting the infeed "Operation" signal on the CX32.
Additional references
For a detailed description of the control words and status words of the PROFIdrive message
frames for SINAMICS S120 drives, see the SINAMICS S120 Commissioning Manual.
See also
Interconnecting the infeed "Operation" signal on the CX32 (Page 185)
Commissioning (software)
7.9 Setting up addresses and message frames
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216 Commissioning and Hardware Installation Manual, 11/2010
7.9 Setting up addresses and message frames
Overview
After all SINAMICS components have been configured, addresses must be determined for
the process data exchange between the drive and the controller.
This procedure depends on whether symbolic assignments are used.
With symbolic assignment, the addresses are determined automatically by the
engineering system, see Section Setting up communication for symbolic assignment
(Page 216)
Without symbolic assignment, the determination of the addresses must be started
manually, see Section Message frame configuration (Page 216).
7.9.1 Setting up communication for symbolic assignment
The communication for symbolic assignment is set up with the following actions:
Via the SCOUT menu (call the following in the menu: "Project" > "Set up communication
for symbolic assignment")
at "Download project to target system"
at "Save project and compile changes"
When setting up the communication, the message frames, BICO interconnections and
addresses are set up for the entire project.
See also
Message frame configuration (Page 216)
7.9.2 Message frame configuration
Requirement
You have configured the drive unit.
On the basis of this configuration, one or more of the following actions should be performed:
The automatic PROFIdrive message frame setting for a drive object should be
activated/deactivated
The automatic message frame extension for a drive object should be
activated/deactivated
The automatic address adaptation for a drive object should be activated/deactivated
PROFIdrive message frames should be configured for drive objects
Commissioning (software)
7.9 Setting up addresses and message frames
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 217
The addresses should be set up
Message frames should be extended manually
Procedure
Proceed as follows:
In the project navigator, open the "Communication" > "Message frame configuration" entry
under "SINAMICS_Integrated".
The "SINAMICS Integrated - Message Frame Configuration" dialog box is displayed with the
PROFIdrive PZD message frames tab.
The dialog box lists all the available drive objects. The possible setting options are described
in the following.

Note
When using the symbolic assignment, the default setting does not have to be changed or
configured.

Note
When using the symbolic assignment, the default setting does not have to be changed or
configured.


Figure 7-44 Message frame configuration
Commissioning (software)
7.9 Setting up addresses and message frames
SIMOTION D4x5
218 Commissioning and Hardware Installation Manual, 11/2010
Table 7- 7 Explanation of the figure
Number Meaning

Selection of a message frame
The drive message frames (message frames 1 ... 6 and message frame 1xx) are defined in accordance
with the PROFIdrive specification and can be selected based on the required functional scope.
You can transfer the signals of the I/Os or the global measuring inputs, for example, via the message
frames 39x. Message frame 39x is also required for the time synchronization between SIMOTION and
SINAMICS.
Free message frame configuration with BICO allows you to define your own message frame.
Free message frame configuration with p915/p916 (for TM15/17).
Message frames 37x for control of the infeed.

The "Standard/automatic" and "User-defined" settings are only visible if "Use symbolic assignment" is
activated. Using the setting "Standard/automatic" is generally recommended.
The "User-defined" setting allows the automatic message frame setting, message frame extension, and
address adaptation to be deactivated or activated.
"Automatic PROFIdrive message frame setting" allows the message frame to be set by the system
depending on the configured technology (message frame selection, e.g. for infeed, drive, and control unit
incl. onboard I/O).
"Automatic message frame extension" allows the message frame to be extended by the system depending
on the configured technology (e.g. if the technology data block is activated in the axis configuration).
"Permit automatic address adaptation" allows addresses to be adapted by the system in the case of
address offsets, for example. Address offsets can occur, for example, if a message frame is extended and
the adjacent addresses are already occupied by other message frames.
With TM15/TM17 High Feature, "Automatic PROFIdrive message frame setting", "Automatic message frame
extension", and "Automatic address adaptation" cannot be deactivated by design, since for these drive objects
the message frame is always set up in accordance with the parameterized terminal functionality (DI, DO,
output cam, measuring input) and cannot be extended.
"Automatic PROFIdrive message frame setting" and "Automatic message frame extension" must be
deactivated if the message frames are to be configured manually for TM15 DI/DO, TM31, and TB30 and
interconnected with BICO.
See Section Setting up communication for symbolic assignment (Page 216).


Message frame status

Length: Displays the size of the message frame component.
Address: Address area in HW Config. The addresses will be displayed only after the addresses have been set
up.

Displays the SIMOTION object that is interconnected to the SINAMICS object (e.g. axis or encoder).
Commissioning (software)
7.10 Linking an additional encoder (optional)
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 219
Number Meaning

Changing the message frame sequence
Before the alignment, all drive objects without input/output addresses ("---..---") must be moved behind the
objects with valid input/output addresses or those still to be aligned ("???..???").

"Manual" adaptation of the message frame configuration (e.g. when additional data, such as a motor
temperature, is to be transferred via the message frame)

Display of the individual control and status words of the associated message frame.

Setting the addresses (alignment of the addresses with HW Config)
Only the addresses of the respective device are determined (no automatic determination of message frames /
BICO interconnections)


Note
If symbolic assignment is deactivated, the following applies:
If the message frames for drive objects change (drives, terminal modules, etc.), you must set
up the addresses again. The addresses are not updated automatically.

7.10 Linking an additional encoder (optional)
7.10.1 Fundamentals
Using encoders
In addition to a motor encoder, additional encoders can be linked and configured:
Additional encoders on the drive
Encoders with DRIVE-CLiQ interface
Encoders connected to a CU310 or CUA32 via the onboard encoder interface
Encoders connected to SIMOTION D via an SMx module
Additional encoders on SIMOTION D
Encoders connected via PROFIBUS
Encoders connected via PROFINET
Commissioning (software)
7.10 Linking an additional encoder (optional)
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220 Commissioning and Hardware Installation Manual, 11/2010
Configuring additional encoders
The additional encoder can be used in SIMOTION, for example, as:
Machine encoder (second encoder = direct measuring system)
A direct measuring system measures the technological parameter directly, i.e. without the
interference of influences such as torsion, backlash, slip, etc. This can facilitate improved
smoothing of mechanical influences by means of the closed-loop control. If you use a
second encoder as a machine encoder, you can work with the encoder changeover
function.
External encoders
You can use the external encoder to record an external master value, for example.
Encoder for hydraulic axes
Encoders for the implementation of cam controllers
7.10.2 Additional encoders on the drive
The following options are available for configuring additional encoders on the drive:
Configuration of a second encoder on the drive
Configuration of an encoder as drive object (as of SINAMICS firmware V4.3).
The following options are available for configuring additional encoders on the drive.
Second encoder on the drive
The configuration of a second encoder on the drive is useful when the second encoder value
is also to be used for this drive (e.g. motor or machine encoder). Note that only a maximum
of two encoder values can be transferred via PROFIdrive message frames.
In principle, the second encoder value can be freely used (e.g. for acquisition of an external
master value), however the use of an encoder as a separate drive object (drive object
DO encoder) is preferable because of the clear functional separation.

Figure 7-45 Configuration of a second encoder on the drive
Commissioning (software)
7.10 Linking an additional encoder (optional)
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 221
Encoder as drive object
The configuration of an encoder as drive object (drive object DO encoder) has the advantage
that this encoder can be used independently of a configured drive (e.g. for acquisition of a
master value).
The configuration is performed by inserting an encoder via the project navigator.
The DO encoder is only available as of SINAMICS V4.3, i.e. only available on control units of
the latest generation (e.g. SINAMICS S120 CU320-2, SIMOTION D4x5-2, CX32-2 --- but not
for the SINAMICS Integrated of a D4x5 and CX32)

Figure 7-46 Configuration of an encoder as drive object
7.10.3 Additional encoders via PROFIBUS/PROFINET
Additional encoders for the encoder integration can be connected via PROFIBUS or
PROFINET. The following options are available:
Encoder interconnection using a PROFIdrive message frame (encoder with message
frame type 81)
Encoder interface as a direct value in the I/O area
Additional references
Detailed information is contained in the
SIMOTION TO Axis, Electric/Hydraulic, External Encoder Function Manual
Commissioning (software)
7.11 Symbolic assignment of I/O variables (PROFIdrive message frame / drive parameters)
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222 Commissioning and Hardware Installation Manual, 11/2010
7.11 Symbolic assignment of I/O variables (PROFIdrive message frame /
drive parameters)
7.11.1 Symbolic assignment of I/O variables to the PROFIdrive message frame of the
TO axis
You can assign I/O variables from the address list which you require for display and
diagnostic purposes, for example, to individual components (status word, for example) of the
PROFIdrive message frame using the assignment dialog. Only components suitable for the
data type of the I/O variable are displayed. If no data type is specified at the I/O variable, this
is determined via the assignment partner after the selection.

Figure 7-47 Assignment of I/O variables to the PROFIdrive message frame
7.11.2 Symbolic assignment of I/O variables to drive parameters
I/O variables from the address list can be assigned to drive parameters using the assignment
dialog. Only parameters suitable for the data type of the I/O variable are displayed. If no data
type is specified at the I/O variable, this is determined by the parameter selection.
An extension of the standard message frame is created automatically for the transfer of the
parameters to/from the drive.
Commissioning (software)
7.11 Symbolic assignment of I/O variables (PROFIdrive message frame / drive parameters)
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 223
Procedure
1. Open the assignment dialog box from the address list (view of all addresses).
The assignment dialog opens with the corresponding assignment partners.
2. Click the button in the parameter selection line to open the parameter list.

Figure 7-48 Assignment dialog for drive parameters
Commissioning (software)
7.11 Symbolic assignment of I/O variables (PROFIdrive message frame / drive parameters)
SIMOTION D4x5
224 Commissioning and Hardware Installation Manual, 11/2010
3. Select the desired signal source (e.g. DO drive). Then select the required parameter.

Figure 7-49 Dialog box for the DO and parameter selection
4. Click "OK" to accept the selection.
Commissioning (software)
7.11 Symbolic assignment of I/O variables (PROFIdrive message frame / drive parameters)
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 225
5. The desired SINAMICS parameter is assigned to the I/O variable in the interconnection
dialog box.

Figure 7-50 Assigned drive parameters
6. Click "OK" to accept the assignment.
The following table shows the possible types of assignment:

Name of the assignment Data type Direction Transferrable BICO parameters
BICO_IW.<parameter number> WORD Input All CO parameters (BICO source)
BICO_QW.<parameter number> WORD Output All CI parameters (BICO sink)
BICO_ID.<parameter number> DWORD Input All CO parameters (BICO source)
BICO_QD.<parameter number> DWORD Output All CI parameters (BICO sink)
Syntax of the assignment names
A number of parameters (separated by periods) are specified for outputs (SINAMICS side
= received data) which can be interconnected with a number of BICO sinks.
If the transferred parameter is on another drive object (DO), the DO name precedes the
parameter. "#" is used as a separator between the DO name and the parameter.
Individually transferred bits of a parameter appear in brackets [x].
Commissioning (software)
7.12 Configuration of drive-related I/Os (with symbolic assignment)
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226 Commissioning and Hardware Installation Manual, 11/2010
7.12 Configuration of drive-related I/Os (with symbolic assignment)
Overview
SIMOTION D4x5, the CX32 controller extension as well as the SINAMICS S110/S120
control units and additional components (TB30, TMs) have I/Os that can be used by the
drive unit and SIMOTION.
So that I/Os, which were originally assigned to SINAMICS can be used by SIMOTION they
must be interconnected to a message frame.
Symbolic assignment
As of version V4.2, SIMOTION SCOUT supports the symbolic configuration of I/Os. "Use
symbolic assignment" must be activated for this purpose (see also Section Symbolic
assignment/adaptation (Page 135))
The symbolic assignment simplifies the configuration significantly:
Table 7- 8 Comparison of configuration with/without symbolic assignment
With symbolic assignment Without symbolic assignment
Configuring message frames So that SIMOTION can use
SINAMICS I/Os, the required message
frames are created automatically
Message frames must be set manually
(either predefined message frame
(e.g. 39x) or free message frame
configuration)
BICO interconnections The required BICO interconnections
are made automatically (I/Os are
interconnected to message frame)
With predefined message frames
(e.g. 39x), the BICO interconnections
are made automatically
With free message frame configuration
with BICO, the interconnection must be
made by the user
Parameterization the I/O functionality
(e.g. measuring input)
Parameterization via screen forms Parameterization via screen forms and
partly via parameters in the expert list
Handling of I/O addresses Handling of addresses is not required
because of symbolic assignment
I/O addresses must be determined
Setting up addresses Addresses are set up automatically,
see also Section Setting up
communication for symbolic
assignment (Page 216)
Addresses must be set up manually,
see also Section Message frame
configuration (Page 216)
Only the configuration with symbolic assignment is described in the following. For further
information on the configuration of drive-related I/Os without symbolic assignment, see
Appendix
Configuration of drive-related I/Os (without symbolic assignment) (Page 323).
Commissioning (software)
7.12 Configuration of drive-related I/Os (with symbolic assignment)
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 227
Procedure
The configuration of the I/Os is divided into two basic steps:
1. Configuration of the I/O terminals (Page 227). The functionality of an I/O channel is
configured (e.g. configuration of a DI/DO as digital output)
2. Configuration of the technology objects and I/O variables (Page 230).
The access of technology objects and I/O variables to I/Os is configured.
The configuration is performed symbolically, whereby only "function-compatible" I/O
channels are offered for selection.
Example:
For the TO measuringInput, only symbolic assignments of the type MI (measuring input)
are offered for selection.
The required message frames and the interconnection are then set automatically by the
engineering system.
See also
Configuration of drive-related I/Os (without symbolic assignment) (Page 323)
7.12.1 Configuration of the I/O terminals
The following table provides an overview of the configuration options for the I/O terminals of
various modules.
Table 7- 9 Overview of the configuration of the I/O terminals
Use of the I/Os by Configuration of the I/O terminals Supports symbolic
assignment
Module
SIMOTION SINAMICS
SIMOTION D4x5-2
- X122/X132
- X142

X
1)

X

X
-

On the drive unit (CU)
On the D4x5-2 (HW Config)
As of SIMOTION V4.2
SIMOTION D4x5 X
1)
X On the drive unit (CU) As of SIMOTION V4.2
CX32-2,
CX32
X
1)
X On the drive unit (CU) As of SIMOTION V4.2
SINAMICS S110
CU305
X
1)
X On the drive unit (CU) As of SINAMICS V4.3
SINAMICS S120
- CU310
- CU320
- CU320-2
X
1)
X On the drive unit (CU)
- As of SINAMICS V2.6.2
- As of SINAMICS V2.6.2
- As of SINAMICS V4.3
TB30, TM15 DI/DO,
TM31
X
1)
X On the drive unit (TB30 or TM) Yes
Commissioning (software)
7.12 Configuration of drive-related I/Os (with symbolic assignment)
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228 Commissioning and Hardware Installation Manual, 11/2010
Use of the I/Os by Configuration of the I/O terminals Supports symbolic
assignment
TM41 X
1)
X On the drive unit (TM41) Yes
2)

TM15, TM17 High
Feature
X - On the drive unit (TM15
or TM17)
Yes
1)
I/Os are originally assigned to a SINAMICS drive unit and can be assigned to SIMOTION via configuration
2)
TM41 only supports the symbolic assignment for the encoder interface (no symbolic assignment for the DI, DO and AI)


Note
The module hardware for TM15 and TM15 DI/DO is identical. A distinction is only made by
the addition of the component in the SIMOTION SCOUT project navigator using "Inserting
input/output component".

I/Os that are originally assigned to the SINAMICS drive unit can also be used by SIMOTION
via configuration.
An output is always only exclusively available for the SINAMICS drive unit or SIMOTION.
An input used by SIMOTION can also be interconnected on the drive side.
The configuration of the I/O terminals is described in detail in the following:
Configuration of the D4x5 I/Os (terminal X122/X132) (Page 228)
Configuration of the CX32/CU3xx/TB30/TMxx I/O terminals (Page 229)
7.12.1.1 Configuration of the D4x5 I/Os (terminal X122/X132)
Procedure
The I/Os of terminals X122 and X132 are originally assigned to the drive unit. The
configuration is therefore performed via the drive unit ("SINAMICS_Integrated" >
"Control_Unit" > "Inputs/outputs).
The properties of the I/O channel can be configured in the parameterization dialog box. With
the bidirectional digital inputs/outputs, for example, an I/O channel can be:
Parameterized as input or output
Inverted
BICO-interconnected (use as drive I/O)
Used as digital input for SIMOTION with "DI (SIMOTION)"
Commissioning (software)
7.12 Configuration of drive-related I/Os (with symbolic assignment)
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Commissioning and Hardware Installation Manual, 11/2010 229
Used as digital output for SIMOTION with "DO (SIMOTION)"
Used as global measuring input for SIMOTION with "Measuring input (SIMOTION)"

Figure 7-51 Configuration of the D4x5 I/Os (terminal X122/X132)

7.12.1.2 Configuration of the CX32/CU3xx/TB30/TMxx I/O terminals
The configuration is performed in a similar way as for the onboard I/Os X122/X132 for the
SIMOTION D4x5, i.e. I/Os can be
BICO-interconnected (use as drive I/O)
Used by SIMOTION
See also Section Configuration of the D4x5 I/Os (X122/X132) (Page 228)

Note
If symbolic assignment is subsequently activated for a project in which message frames
have already been configured and interconnected, these can be changed together with the
BICO interconnections!
For this reason, make a backup copy of your project before activating the symbolic
assignment. TB30, TM15 DI/DO and TM31 are especially affected.
See also Section Symbolic assignment / adaptation (Page 135)

Commissioning (software)
7.13 Configuration of the technology objects and I/O variables
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230 Commissioning and Hardware Installation Manual, 11/2010
7.13 Configuration of the technology objects and I/O variables
7.13.1 Configuration of global measuring inputs
Overview
The type of measuring input must be selected during the configuration of the TO
measuringInput.
The following measuring input types are available:
Table 7- 10 Measuring input types
Measuring input types Explanation
Standard (global
measuring input)
Compared with the drive-related local measuring inputs, global measuring
inputs have extended functionality and also support a symbolic
configuration.
They are therefore set as standard.
Drive-related (local
measuring input)
The drive-related local measuring inputs are configured via drive
parameters, see Section Configuration of drive-related I/Os (without
symbolic assignment) (Page 323) in the appendix.
Listening measuring
input
Through the configuration of a listening measuring input, measuring can be
performed simultaneously on several axes or external encoders with one
measuring input. Detailed information can be found in the SIMOTION
Motion Control Output Cams and Measuring Inputs Function Manual.
A detailed comparison of "local" and "global" measuring inputs as well as an overview of
which modules support local or global measuring inputs can be found in Section
Configuration of drive-related I/Os (without symbolic assignment) (Page 323) in the
appendix.
Procedure
If a global measuring input is selected, it must be assigned a hardware input.
To do this, open the assignment dialog box via and select a free (i.e. not yet used) I/O.

Note
Only those I/Os are displayed that have the appropriate measuring input functionality (MI_xx
[channel name, terminal number]). If no suitable I/Os are displayed, you must first configure
the I/Os (I/O must be configured as "measuring input")

Commissioning (software)
7.13 Configuration of the technology objects and I/O variables
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 231

Figure 7-52 Configuration of a global measuring input for the D4x5
Detailed information on the configuration of the TO measuringInput can be found in the
SIMOTION Output Cams and Measuring Inputs Function Manual.
7.13.2 Configuration of local measuring inputs
Local measuring inputs are drive-related measuring inputs. The configuration is performed
via drive parameters.
For further details, see:
Section Configuration of drive-related I/Os (without symbolic assignment) (Page 323) in
the appendix
SIMOTION Output Cams and Measuring Inputs Function Manual
See also
Configuration of drive-related I/Os (without symbolic assignment) (Page 323)
7.13.3 Configuration of output cams / cam tracks
Overview
The type of cam output must be selected during the configuration of the TO outputCam and
TO camTrack.
Commissioning (software)
7.13 Configuration of the technology objects and I/O variables
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232 Commissioning and Hardware Installation Manual, 11/2010
The following output types are available:
Table 7- 11 TO outputCam / TO camTrack output types
Cam output on... Explanation
Cam output (CAM) The cam output is performed on the basis of an internal time stamp.
The temporal resolution of the cam output depends on the hardware
used.
Supported hardware:
SIMOTION D4x5-2 (terminal X142): Resolution 1 s
TM17 High Feature: Resolution 1 s
TM15: Typical resolution 125 s (DRIVE-CLiQ cycle clock)
High-speed digital output
(DO)
The cam output is performed via onboard outputs of the SIMOTION
CPU. The output is via a hardware timer, whereby the cam output is
achieved with a resolution with respect to time < servo cycle clock.
Supported hardware:
SIMOTION D4x5 (terminal X122, X132)
SIMOTION D410 (terminal X121)
SIMOTION C240, C240 PN (terminal X1)
Standard digital output
(DO)
The output cam calculations are performed in the execution cycle (IPO
or IPO2 cycle clock or in the servo cycle clock).
The actual cam output is performed in the servo cycle clock. The
resolution with respect to time of the cam output is generally reduced
by the output cycle of the I/O used.
The resolution is therefore dependent as follows:
For the standard I/O (e.g. ET 200), on the cycle time of the bus
system (PROFIBUS DP / PROFINET IO)
For the TM15 / TM17, on the cycle time of the bus system
(PROFIBUS Integrated / PROFIBUS DP / PROFINET IO)
For the TM15 DI/DO, TM31, TM41, TB30, on the configured
sampling time:
cu.p0799 (CU inputs/outputs sampling time) for the TB30 and
onboard outputs
p4099 (TMxx inputs/outputs sampling time) for TM15 DI/DO,
TM31 and TM41
Supported hardware:
Onboard outputs (SIMOTION D, CX controller extension,
SINAMICS CU3xx control unit)
Centralized I/O (SIMOTION C)
Distributed I/O via PROFIBUS DP / PROFINET IO (e.g. ET 200,
etc.)
Drive-related I/O (TM15, TM15 DI/DO, TM17 High Feature, TM31,
TM41, TB30)
Commissioning (software)
7.13 Configuration of the technology objects and I/O variables
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 233
Procedure
To achieve the best possible output cam resolution on the onboard I/Os of a SIMOTION
D4x5, activate the output and select "Cam output on fast digital output (DO)".
Then assign a hardware output. To do this, open the assignment dialog box via and
select a free (i.e. not yet used) I/O.

Note
Only those I/Os are displayed that have the appropriate functionality (DO_xx [channel name,
terminal number]). If no suitable I/Os are displayed, you must first configure the I/Os (I/O
must be configured as "DO")


Figure 7-53 Configuration of an output cam for the D4x5
Detailed information on the configuration of the TO outputCam / TO camTrack can be found
in the SIMOTION Output Cams and Measuring Inputs Function Manual.
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234 Commissioning and Hardware Installation Manual, 11/2010
7.13.4 Configuration of the I/Os (variables / TO axis)
I/O variables
The I/O variables are configured via the address list. Components that support a symbolic
assignment can be configured without I/O addresses. Components that do not support
symbolic assignment (e.g. standard PROFIBUS I/O) are configured via I/O addresses.

Figure 7-54 Address list
TO Axis
The symbolic assignment of I/Os is also supported by the TO axis (e.g. for a HW limit
switch).
Substitute values for I/O variables
Substitute values cannot be specified for input variables of the BOOL data type. If you do
require substitute values however, proceed as follows:
1. Assign a digital input (e.g. SINAMICS_Integrated.Control_Unit.DI_0 [DI 0, X122.1]) to an
input variable of the BOOL type (e.g. sensor).
2. Create a global variable (e.g. all_inputs) (at least data type WORD, e.g.
SINAMICS_Integrated.Control_Unit.DI_0_15).
3. Configure the substitute value
The appropriate bit of the substitute value must then contain the substitute value for the
BOOL variable.
In the same way, you can assign a substitute value to a BICO parameter.
For various SINAMICS drive objects, higher-level types are available for the assignment of
substitute values.

Figure 7-55 Configuration of substitute values
Commissioning (software)
7.14 DMC20/DME20 DRIVE-CLiQ hub
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Commissioning and Hardware Installation Manual, 11/2010 235
7.14 DMC20/DME20 DRIVE-CLiQ hub
7.14.1 Hub properties
DRIVE-CLiQ hub characteristics
The DMC20 and DME20 DRIVE-CLiQ hub modules are used to implement point-to-point
distribution of a DRIVE-CLiQ line. With the DMC20/DME20, an axis grouping can be
expanded with four DRIVE-CLiQ sockets for additional subgroups.
DMC20 is the hub for the control cabinet configuration
DME20 is the hub for use without a control cabinet (IP67 degree of protection).
The modules are especially suitable for applications which require DRIVE-CLiQ nodes to be
removed in groups, without interrupting the DRIVE-CLiQ line and therefore the data
exchange.
Application examples
Typical applications of DRIVE-CLiQ hubs are encoder expansion and hot plugging.
In an encoder expansion, direct measuring systems are connected. For example, these
are attached directly to the machine in the control cabinet. Several encoders can be
connected to one hub in the cabinet.
Hot plugging is the option for changing motor modules while in operation. To do so, the
motor modules are connected via a DRIVE-CLiQ hub in the form of a point-to-point
topology. This means they can be deactivated without impairing downstream components
(via cascading).


Note
Cascading is permitted one time only (from hub to hub).
Additional references
Additional information on the DMC20/DME20 DRIVE-CLiQ is contained in the
SIMOTION D4x5 Manual.
SINAMICS S120 Control Units and Additional System Components Manual.
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7.15 TM41 Terminal Module
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236 Commissioning and Hardware Installation Manual, 11/2010
7.14.2 Creating a DMC20/DME20 DRIVE-CLiQ hub
Introduction
A DMC20/DME20 can be inserted directly in the project navigator. The hub is not wired
when you insert the DMC20/DME20 and is displayed in the topology tree in the component
storage. The hub has to be wired manually.
Procedure
1. Right-click "Topology" in the project navigator.
2. Select the "Insert new object" > "DRIVE-CLiQ hub" command from the context menu and
confirm with "OK".
3. Double-click "Topology" to display the topology tree.
In the topology tree, the hub is stored in the component archive.
4. Drag-and-drop the hub to the required DRIVE-CLiQ interface.
The components connected to the hub are displayed in the topology tree.
Result
The added hub is displayed for the "Topology" entry in the project navigator. All components
connected to a hub are also displayed during an automatic configuration.
7.15 TM41 Terminal Module
7.15.1 Overview
The TM41 terminal module can be used to expand the number of digital I/O and of analog
inputs within a drive system. TM41 also returns TTL signals which emulate an incremental
encoder, for example, for a master control system.
The emulated encoder signal has the signal characteristic of an incremental TTL encoder (A
track, B track, R track). The resolution of the encoder signal can be specified in the
configuration.

Note
The digital I/Os and the analog input can be interconnected with BICO configuration in the
same way as a TM31.

Commissioning (software)
7.15 TM41 Terminal Module
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Commissioning and Hardware Installation Manual, 11/2010 237
The TM41 encoder interface (incremental encoder representation) can
Be interconnected with an encoder signal of the control unit by means of
parameterization, e.g. sin/cos incremental encoders. For detailed information, see the
SINAMICS manuals.
From the SIMOTION viewpoint, can be accessed as axis. This allows you to return the
axis position (a master value) as an encoder signal to a second controller, for example.
The configuration can be performed symbolically and is described in the following.


Note
TM41 only supports the symbolic assignment for the encoder interface (no symbolic
assignment for the DI, DO and AI).
Configuring the TM41 involves the following steps:
Configuring TM41 at SINAMICS Integrated
Configuring TM41 using the axis wizard.
7.15.2 Configuring TM41 at SINAMICS Integrated
TM41 can be configured after you completed the configuration of SINAMICS Integrated.
Proceed as follows:
1. Double-click "Insert input/output component" at "Input/output component" in the project
navigator.
2. Select TM41 from the "Drive object type" field of the "Insert Input/Output Component"
dialog box and assign a unique name to the module.
3. Confirm your entry with "OK".
The TM41 is inserted in the project navigator by the name you entered.
4. Double-click "Inputs/outputs". The "Inputs/Outputs Properties" dialog box of TM41 opens.
5. Set "SIMOTION" as the operating mode on the "Pulse encoder emulation" tab, and make
the settings for the emulated sensor signal.
6. Double-click "Configuration" under "SINAMICS_Integrated" in the project navigator and
select the "PROFIdrive message frame" tab.
7. Click "Close" to exit the dialog box.
You programmed TM41 and aligned it with HW Config.
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7.15.3 Configuring TM41 using the Axis Wizard.
After configuring the TM41 for a SINAMICS Integrated device in the project navigator, you
can interconnect it with an axis using the axis wizard. The wizard implements the TM41 as
drive device.
1. Open the axis wizard and create a positioning or synchronization axis (electrical).
2. Step the axis wizard forward until the "Drive Assignment" dialog box opens.
3. Select "SINAMICS_Integrated" as the drive device and "TM41" as the drive.
TM41 operates as setpoint sink of the axis with this setup.

4. Run through the wizard to the end.
Detailed information on configuring incremental encoder emulation with the TM41 can be
found in:
FAQ list http://support.automation.siemens.com/WW/view/en/27554028
SIMOTION Utilities & Applications.
SIMOTION Utilities & Applications is part of the scope of delivery of SIMOTION SCOUT.
7.16 Optimizing drive and closed-loop controller
7.16.1 Overview of automatic controller setting
Overview
For the controller optimization of the drive, SIMOTION SCOUT offers a wizard for the
automatic controller setting.
In the "Automatic Controller Setting" screen form, you can configure an automatic setting for
the speed controller and the DSC (dynamic servo control) position controller for SINAMICS
drive units. The necessary steps for this calculation can be controlled from this screen form.
The parameter values calculated for the speed controller or position controller are displayed;
these can then be transferred online to the drive or axis on the controller.
You can set the controller automatically using the menu command "Target system" >
"Automatic controller setting".
For a detailed description of the parameters that can be defined, to the SIMOTION SCOUT
Online Help.
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Requirements
You have configured a SINAMICS drive.
The configured drive is operated in the "Servo" drive object type.
Closed-loop control takes place with the motor encoder.
There is an online connection to the relevant drive unit.
Procedure
Automatic controller setting involves the following steps:
1. Setting the speed controller
2. Setting the position controller


Note
You can cancel automatic controller setting by pressing the SPACEBAR.
The step currently being executed is aborted.
The drive enable is canceled.
Additional references
Information on the controller structure can be found in the SIMOTION TO Axis,
Electric/Hydraulic, External Encoder Function Manual.
In addition to automatic controller setting, SIMOTION SCOUT also offers the option of
optimizing the drive and controller manually by means of measuring functions, trace, and
function generator (see Measuring functions, trace, and function generator (Page 242) and
Manual speed controller optimization (Page 243) in this manual).
7.16.2 Automatic speed controller setting
Characteristics
The automatic speed controller setting has the following features:
Attenuation of resonances in the speed-controlled system
Automatic setting of the gain factor Kp and the integral time Tn of the speed controller
The speed setpoint filter and the reference model are not changed
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Procedure
To perform an automatic setting of the speed controller, proceed as follows:
1. Select the "Target system" > "Automatic controller setting" menu command.
2. Select the drive unit and the drive.
3. Select the "Speed controller" from the "Controller selection".
4. Click "Assume control priority" to assume control priority.
5. Press the "Drive On" button to enable the drive.
Perform these steps (1 to 4) in automatic mode or as individual steps.
6. Click "Transfer" to transfer the calculated parameter values for the speed controller to the
drive.
7. Disable the drive by clicking the "Drive Off" button.
8. Click "Give up control priority" to give up control priority of the PG/PC.
9. Save the online parameters.
You can now transfer the automatically set parameters to the project.
Backing up parameters
Proceed as follows to back up the parameters:
1. In the project navigator, select the SINAMICS unit with the drive for which you want to
perform the automatic setting
2. Select "Target device" > "Copy RAM to ROM" in the context menu.
3. Select "Target device" > "Load CPU / drive unit to PG" in the context menu.
If necessary, the automatic controller settings can be verified with the measuring functions.
7.16.3 Automatic position controller setting
Introduction
In the "Automatic Controller Setting" screen form, you can select the SINAMICS drive unit
and the drive for which you want to carry out an automatic DSC position controller setting.
The necessary steps for this calculation can be performed from this screen form. The
calculated Kv value is displayed and can then be accepted online in the configuration data of
the axis that is assigned to the drive.
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Requirements
In addition to the General requirements for the automatic controller setting, the following
boundary conditions apply for setting the position controller:
DSC is required for the position controller setting.
Tip:
Activate the project setting "Use symbolic assignment" and select the Standard/Automatic
option for the axis-drive communication when configuring the drives. You automatically
use DSC for the servo drives with these settings.
The speed controller has already been configured (e.g. with the automatic speed
controller setting).
At least one axis is connected to the SINAMICS drive (servo).
An online connection to the SIMOTION device must be established to transfer the results
of the automatic position controller setting.
The balancing filter is not changed.
For operation without precontrol, the equivalent time constant of the position controller
must be adjusted manually by the user (PositionTimeConstant = 1/Kv).
Vibration on the load side is not taken into account for the position controller setting.
Procedure
To perform an automatic setting of the position controller, proceed as follows:
1. Select the "Target system" > "Automatic controller setting" menu command.
2. Select the drive unit and the drive (axis).
3. Select the "Position controller (DSC)" from "Controller selection".
4. Click "Assume control priority" to assume control priority.
5. Press the "Drive On" button to enable the drive.
Perform the steps either in automatic mode or as individual steps.
6. Select the axis data sets to which the Kv factor is to be transferred.
7. Click "Transfer" to transfer the calculated Kv factor to the axis data sets.
8. Disable the drive by clicking the "Drive Off" button.
9. Give up the control priority of the PG/PC.
10. Save the online parameters.
You can now transfer the automatically set parameters to the project.
Backing up parameters
Proceed as follows to back up the parameters:
1. In the project navigator, select the SIMOTION unit with the axis for which you want to
perform the automatic setting
2. Select "Target device" > "Copy current data to RAM" in the context menu.
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3. Select "Target device" > "Copy RAM to ROM" in the context menu.
4. Select "Target device" > "Load CPU / drive unit to PG" in the context menu.
If necessary, the automatic controller settings can be verified with the measuring functions.
7.16.4 Measuring functions, trace, and function generator
Drive optimization
Drive optimization is part of commissioning and can be performed with SIMOTION SCOUT.

CAUTION
Controller optimization may only be performed by skilled personnel with control engineering
knowledge.

Controller optimization
Various measuring functions are available for controller optimization of the drive. These
measuring functions enable the control of the higher-level control loop to be selectively
switched off and the dynamic response of individual drives to be analyzed through simple
parameter assignment. The function generator and the trace recorder are used.
The control loop is supplied with the ramp-function generator signal at a specific point (e.g.,
speed setpoint), and the signal from the trace recorder is recorded at another point (e.g.,
speed actual value).
Channel1
Channel2
Channel3
Channel4
n_set
n_act
i_act
l_set
n_set
i_act
n_act
Trace
recorder
Function
generator
Speed
controller
Current
regulator
Controlled
system

Figure 7-56 Optimizing a closed-loop controller

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7.16 Optimizing drive and closed-loop controller
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Commissioning and Hardware Installation Manual, 11/2010 243
Depending on the form of controller optimization to be performed, it is possible to define the
quality (e.g. signal form, amplitude, transient recovery time) of the disabled signal, the
measuring duration for step functions in the time range, or the bandwidth and number of
averaging operations in the frequency range for the trace. The analytical and graphical
evaluation can then be performed accordingly (FFT diagram, Bode diagram).
The following measuring functions are available:
Setpoint step-change at current controller
Reference frequency response at current controller
Setpoint jump at speed controller
Disturbance step-change at speed controller
Reference frequency response at speed controller
Disturbance frequency response at speed controller
Speed-controlled system (input at current setpoint filter)
Additional references
For additional information about drive optimization, consult the SINAMICS S120
Commissioning Manual.
Additional information on trace and measuring functions, as well as on the function
generator, can be found in the SIMOTION SCOUT Online Help.
7.16.5 Manual speed controller optimization
Requirement
You have already created a project and configured an axis and a drive. You can now
optimize the speed controller.
Procedure
1. Open the project and go to online mode.
2. Click to call the "Measuring Functions" dialog. The activated Service function is
displayed via the LEDs (RUN flashes green at 2 Hz and SU/PF flashes yellow at 2 Hz)
3. Select the drive unit and the drive.
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4. Select "Speed controller setpoint jump".
You can change the values in the following fields: "Settling time", "Amplitude", "Offset",
"Ramp-up time" and "Measuring time".

Figure 7-57 Speed controller measuring function

Four channels can be traced. Certain channels are preassigned, depending of the
measuring function.
5. Download the changes to the drive by clicking (Download parameter assignment).
Starting the measuring function
1. Click "Assume control priority" to assume control priority.
Read the notice that appears and click "Accept" to confirm.
2. Press the "Drive On" button to enable the drive.
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3. Click (Start measuring function) to start the measuring functions.
The axis is moved during the measurement. For this reason, a safety message that
allows the process to be aborted is displayed.
After reading the notices, you can begin the measurement with "Accept" or abort it with
"Abort".
4. The traced signals are represented on the "Timing Diagram" tab.

Figure 7-58 Timing diagram before parameter change
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Adjusting the P-Gain
You can adjust the P-gain of the controller to optimize the transient response.
1. In the project navigator under the corresponding drive, for example, Servo_1, use the
menu command "Open-Loop/Closed-Loop Control" > "Speed Controller" to display the
"Speed Controller with Encoder" dialog.
2. Enter an appropriate value in the "P-gain" field and the "Integral time" field.
CAUTION

The values entered take immediate effect.

Figure 7-59 Entering P-gain

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7.17 Downloading and storing user data
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3. For verification purposes, perform the measurement again.
4. With the modified parameters, the controller displays a much better transient response. If
necessary, you can continue changing the value until the transient response is optimal.

Figure 7-60 Measurement with modified P-gain
7.17 Downloading and storing user data
Overview
After commissioning the SIMOTION D4x5, we recommend that you back up the user data
(programs, configuration data, and parameter assignments) to the CF card.
Loading user data
The menu command "Target system" > "Load" > "Download project to target system" is used
to transfer the following data from the SIMOTION SCOUT engineering system to the "non-
volatile data" area of the SIMOTION D4x5:
Configuration data
Programs
Parameter assignments
Technology packages
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248 Commissioning and Hardware Installation Manual, 11/2010
The hardware configuration of SIMOTION D4x5 and the retain variables are also saved to
the "non-volatile data" area.

Note
Using the menu:
"Target system" > "Load" > "Load project to target system" downloads all of the project
data to the target system.
"Target system" > "Load" > "Download CPU / drive unit to target device" only downloads
the data of the selected device / drive element to the target device.
After the SIMOTION D4x5 is switched off, the contents of the "volatile data" area are lost.

Additional information on the SIMOTION SCOUT Engineering System can be found in the
SIMOTION SCOUT Configuration Manual.
Storing user data
The "Copy RAM to ROM" function is used in SIMOTION SCOUT to save the following data
from RAM to the CF card:
Technology packages and user data (units, configuration data, parameter assignments,
task configuration) from the "volatile data" area
Current values are copied to the "volatile data" area, depending on the settings in
SIMOTION SCOUT


Note
The "Copy RAM to ROM" function does not save the current values of the retain variables
to the CFcard.
You have the following options for backing up the current values of retain variables to the
CF card:
In the user program
Use the "_savePersistentMemoryData" system function for this purpose.
Using a switch position (SIMOTION D4x5 Service selector switch) or IT DIAG.
See Section Backing up diagnostics data and non-volatile data (Page 310).
With the SCOUT functions "Back up variables" and "Restore variables", you also have the
option of backing up to your PC and restoring data that was changed during operation and
only stored in the runtime system.
Execute the "Copy RAM to ROM" function separately for the SINAMICS Integrated. This
requires that the drive element has been selected in the project navigator.
See also
Properties of the user memory (Page 89)
Commissioning (software)
7.18 Deleting data
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Commissioning and Hardware Installation Manual, 11/2010 249
7.18 Deleting data
7.18.1 Overview of data deletion
The SIMOTION D4x5 memory described in the "user memory concept" can be deleted in
various gradations. This enables you to determine whether data in your system should be
deleted completely or partially.
You have the following options for deleting SIMOTION C4x5 data:
Memory reset of SIMOTION D4x5 (Page 249)
Deleting user data on CF card (Page 252)
Setting SINAMICS Integrated to the factory settings (Page 253)
Setting SIMOTION D4x5 to the default settings (Page 253)
Deleting/restoring non-volatile data (Page 317)
7.18.2 Overall reset of SIMOTION D4x5
Introduction
During the overall reset, the memory of the SIMOTION D4x5 and the non-volatile data in the
SRAM (with the exception of the communication configuration (baud rates, network
addresses, etc.)), are deleted. The data on the CF card are retained during the memory
reset.
You must perform a memory reset of SIMOTION D4x5:
When you want to undo changes you have made to your user data (programs,
configuration data, parameter assignments) that you have not backed up with the "Copy
RAM to ROM" menu command.
If the STOP LED is flashing (yellow and slowly) to indicate that the SIMOTION D4x5 is
requesting a memory reset.
If the non-volatile data and the project on the CF card do not match and an error occurs
(diagnostic buffer entry).
You can perform the memory reset online via SIMOTION SCOUT or offline via the mode
selector on the SIMOTION D4x5.
Data deleted on memory reset
The following data is deleted during a memory reset:
User data (units, configuration data, parameter settings, task configuration)
Technology packages
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Retain TO (absolute encoder adjustment)
Retain variables
Retain variables are variables in the interface or implementation section of a UNIT that
are declared with VAR_GLOBAL RETAIN or global device variables with the RETAIN
attribute.


Note
Absolute encoder data is deleted during a memory reset operation and must therefore be
readjusted after the memory reset.
Reset-proof data
The following data is retained during a memory reset:
TCP/IP parameters and DP parameters
Diagnostics buffer
Data saved with the _savePersistentMemoryData, _saveUnitDataSet or
_exportUnitDataSet system functions and with the "Copy RAM to ROM" function
If backup files (PMEMORY.XML/PMEMORY.BAK) have been backed up with
_savePersistentMemoryData, the data in these files are backed up again to the non-
volatile data after the memory reset. Thus, the user can perform a memory reset to force
the backed up non-volatile data to be restored. This also includes the absolute encoder
position.
Licenses
The technology packages and user data (configuration data, programs, parameter
assignments) that were previously backed up to the CF card using the "Copy RAM to ROM"
menu command will be transferred to the "non-volatile data" area of the SIMOTION D4x5
during the next power-up. Thus, an existing configuration on the CF card is loaded to the
SIMOTION device following the memory reset.
Memory reset via SIMOTION SCOUT
You can only perform a memory reset via SIMOTION SCOUT if you are online with the
SIMOTION D4x5.
1. Select the SIMOTION D4x5 in the project navigator of SIMOTION SCOUT.
2. Select "Target device" > "Operating mode" in the context menu to open the "D4x5:
Operating Mode" dialog.
3. Select the STOP mode.
4. Then select MRES mode to perform the memory reset.
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Memory reset with the mode selector
You can perform a memory reset with the mode selector if you are offline with the
SIMOTION D4x5.

CAUTION
Always use an insulated screwdriver to activate the mode selector. Otherwise, static
electricity can destroy the switch.

Proceed as follows to initiate a memory reset:
1. Place the mode selector in the STOP position (switch setting 2, see figure below).

Figure 7-61 Memory reset with the mode selector (STOP position)

2. When the STOP LED is steadily yellow, turn the switch to the MRES position (switch
position 3). The STOP LED starts to flash slowly (slow yellow flashing).
Wait until the STOP LED stops flashing.
3. Turn the switch back to the STOP setting.
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4. You must turn the selector back to the MRES position again within 3 seconds. The
memory reset will now be performed.
The SIMOTION D4x5 has completed the overall reset when the STOP LED lights up
steady yellow.


Note
If you do not return the mode selector to the MRES position (switch setting 3) within 3
seconds (i.e. you allow more time to elapse), under certain circumstances the memory
reset will not take place. You must then repeat the procedure.
5. Now move the mode selector back to the required operating mode.
NOTICE

Note that the MRES position (switch setting 3) during power-up causes the default
settings to be restored. See Setting SIMOTION D4x5 to the default settings (Page 253).
Make sure you do not accidentally switch the power supply OFF/ON in the MRES
selector setting, as this will reproduce the default settings instead of performing the
desired memory reset.
7.18.3 Deleting user data from CF card
Overview
If you want to save a different (new) project to the CF card, it may be necessary to delete
user data from an "old project" (e.g. unit data sets) which might be stored on the CF card
You can delete the user data with SIMOTION SCOUT. This requires you to go online on the
SIMOTION D4x5. The following data is deleted during this operation:
User data from the "volatile data" area
Non-volatile data, with the exception of IP and DP parameters
User data on the CF card (user directories), including the SINAMICS configuration
You can thus continue to go online to the SIMOTION D4x5 with your PG/PC. The licenses
on the CF card are retained.
Deleting user data
1. In SIMOTION SCOUT, open the project you want to modify.
2. Go online with the SIMOTION D4x5.
3. Select the SIMOTION D4x5 in the project navigator and select the "Delete user data on
card" option in the "Target system" menu.
4. Confirm the "Delete user data from card" prompt with "OK".
The user data is deleted and the SINAMICS Integrated goes offline.
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See also
Upgrading technology packages (Page 279)
7.18.4 Restoring the default settings of SINAMICS Integrated
Prerequisite
You must be online to SINAMICS Integrated in order to restore its default settings.
Restoring the default settings
1. Right-click "SINAMICS_Integrated" in the Project Navigator.
2. Select the "Target device > Restore default settings" command from the shortcut menu.
This restores the delivery state of SINAMICS Integrated.
7.18.5 Setting SIMOTION D4x5 to the default settings
Overview
SIMOTION D4x5 is supplied with preset parameters, such as the transmission rate or
PROFIBUS addresses. You can restore the default settings with the mode selector. The
following data are deleted during this operation:
Non-volatile data in the SIMOTION device
The backup copy of the non-volatile data on the CF card
(PMEMORY.XML/PMEMORY.BAK)
User data from the "volatile data" area and on the CF card
The communication configuration (IP and DP parameters) on the CompactFlash Card is
set to the factory settings.
The licenses on the CompactFlash Card are retained.
Restoring default settings with the mode selector
1. The power supply is switched off.
2. Set the mode selector on the SIMOTION D4x5 to MRES (selector setting 3).
Commissioning (software)
7.19 Powering down the system
SIMOTION D4x5
254 Commissioning and Hardware Installation Manual, 11/2010
3. Switch on the power supply.
The backed-up SRAM and the user data are deleted. The default settings are loaded.
SIMOTION D4x5 is in STOP mode.
4. Now use the mode selector to change to the desired operating mode.


Note
The communication parameters are now reset to the default settings (PROFIBUS
address 2, baud rate of 1.5 Mbit/s). The communication configuration for SIMOTION
D4x5 must be repeated.
7.19 Powering down the system
If you wish to shut the system down, you must ensure that all axes and system parts are set
to a safe state. You can set this up by providing a separate motion task, for example.
Once the system is at a standstill, you can switch off the power supply.

Note
You must observe the safety notes for SINAMICS components, which you will find in the
corresponding SINAMICS manuals.

7.20 Configuring Safety Integrated functions
Integrated safety functions
When used in conjunction with SIMOTION D, the integrated safety functions of
SINAMICS S120 provide highly effective practical protection for personnel and machinery.
The following Safety Integrated functions on the basis of the SINAMICS FW V2.6.2 are
currently available:
(Terms in accordance with IEC 61800-5-2)
Safe Torque Off (STO)
Safe Brake Control (SBC)
Safe Stop1 (SS1)
Safe Stop2 (SS2)
Safe Operating Stop (SOS)
Safely-Limited Speed (SLS)
Safe Speed Monitor (SSM)
Commissioning (software)
7.20 Configuring Safety Integrated functions
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 255
Control circuit
The Safety Integrated functions are completely integrated into the drive system. They can be
activated as follows:
Via terminals on the control unit and on the power unit (STO, SBC, SS1 only)
Via terminals on the TM54F terminal module (as of SIMOTION V4.1 SP1)
Via PROFIBUS with PROFIsafe (as of SIMOTION V4.1 SP1 HF6)
Via PROFINET with PROFIsafe (as of SIMOTION V4.2)
The Safety Integrated functions are implemented electronically and therefore offer short
response times in comparison to solutions with externally implemented monitoring functions.

Note
Although SIMOTION does not contain any safety-related functionality, it provides support for
SINAMICS drives that can perform safety-related functions.
The purpose of this support that SIMOTION offers for the safety-related monitoring functions
is to prevent fault reactions at the drive end by ensuring that the drive does not exit the
monitored operating state.

Hardware required
Where safety functions are controlled via the TM54F or via PROFIBUS/PROFINET with
PROFIsafe, at the very least the following hardware versions must be used:
SIMOTION D425: 6AU1425-0AA00-0AA0, product version D
SIMOTION D435: 6AU1435-0AA00-0AA1, product version D
SIMOTION D445: 6AU1445-0AA00-0AA0, product version B
SIMOTION D445-1: 6AU1445-0AA00-0AA1, product version A
SIMOTION CX32: 6SL3040-0NA00-0AA0, product version A
The hardware requirements of the drive components can be found in the SINAMICS S120
Safety Integrated Function Manual.
Commissioning (software)
7.20 Configuring Safety Integrated functions
SIMOTION D4x5
256 Commissioning and Hardware Installation Manual, 11/2010
Quantity structures
The maximum number of servo drives with Safety Integrated functions for each control unit
is:
Table 7- 12 SIMOTION D4x5 quantity structures
Control unit Maximum number of servo drives when safety function is activated
Via CU/EP terminals
(STO, SBC, SS1 only)
Via TM54F terminals Via PROFIBUS with
PROFIsafe
1)

Via PROFINET with
PROFIsafe (as V4.2)
2)

SIMOTION D4x5 6 5 5 5
SIMOTION D4x5
(with CX32)
5 4 4 4
CX32 6 5 4 (V4.1 SP1 HF6)
5 (as of V4.1 SP2)
5
CU320 6 5 5 (as of V4.1 SP2) 4
CU320-2 6 (as of V4.1 SP5) 6 (as of V4.1 SP5) 6 (as of V4.1 SP5) 6 (as of V4.2)
1)
If SIMOTION D is operated as an intelligent DP slave on an F-CPU, a maximum of 32 safety slots can be configured for
each intelligent DP slave in HW Config. If the Safety Integrated functions are controlled via PROFIBUS with PROFIsafe,
one slot in the input area and one slot in the output area are used for each safety axis. This results in a maximum of 16
drives with the Safety Integrated function for each PROFIBUS interface (intelligent DP slave) of the D4x5.
If with SIMOTION D both PROFIBUS interfaces are operated as intelligent DP slave on a F-CPU, the quantity structure
increases to 2 x 16 drives (sum of the drives on the SINAMICS Integrated, CX32 and SINAMICS control units). In this
case however, no PROFIBUS master interface is available for the connection of I/Os, for example.
2)
The maximum permissible quantity structure for the D4x5 is 64 drives with Safety Integrated function (sum of the drives
on the SINAMICS Integrated, CX32 and SINAMICS control units).
Safety Integrated functions with TM54F
Safety Integrated functions are activated via fail-safe digital inputs on the TM54F. This
means that every drive control (SINAMICS Integrated of SIMOTION D4x5, CX32, CU320,
CU320-2, etc.) requires its own TM54F (assuming relevant safety functions are to be used
on the control unit concerned). Only one TM54F can be connected for each
SIMOTION D4x5, CX32 or SINAMICS S120 control unit.
Commissioning (software)
7.20 Configuring Safety Integrated functions
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 257
Safety Integrated functions with PROFIsafe (PROFIBUS example)
Safety Integrated functions are activated via "PROFIsafe on PROFIBUS" safe
communication. Control (F logic) is based on a SIMATIC F-CPU connected via PROFIBUS
with PROFIsafe, e.g. a SIMATIC S7-300 F-CPU (see figure) or an ET 200S IM151-7 F-CPU
with PROFIBUS DP master interface module (not shown in the figure).

Figure 7-62 SIMOTION D, control of F functions via PROFIBUS with PROFIsafe
A function example can be found at
(http://support.automation.siemens.com/WW/view/en/36489289)
Commissioning (software)
7.20 Configuring Safety Integrated functions
SIMOTION D4x5
258 Commissioning and Hardware Installation Manual, 11/2010
Topologies
The topologies that may be used with the SIMOTION D4x5 and CX32 are listed below. In
each case, the description specifies whether the control of Safety Integrated functions is
routed through the drives.
SIMATIC F-CPU (master), connected via PROFIBUS with PROFIsafe to SIMOTION
D4x5 (intelligent DP slave)
Routing to SINAMICS Integrated drives for the D4x5 and CX32, as of V4.1 SP1 HF6
Routing to the drives of a SINAMICS S120 CU as of V4.1 SP2 connected to the D4x5
- CU is connected as slave via PROFIBUS to the DP master interface of the D4x5
- Routing to a CU connected via PROFINET is not possible.
SIMATIC F-CPU (controller), connected via PROFINET with PROFIsafe to
SIMOTION D4x5 (intelligent device)
Routing to SINAMICS Integrated drives for the D4x5 and CX32, as of V4.2
Routing to the drives of a SINAMICS S120 CU as of V4.2 connected to the D4x5
- CU is connected as intelligent device via PROFINET to the PROFINET interface of
the
D4x5 (=controller)
- CU is connected as slave via PROFIBUS to the DP master interface of the D4x5.
The SIMOTION D4x5 is the PROFIBUS master for a fail-safe data exchange broadcast,
e.g. between a SIMATIC F-CPU (e.g. ET 200S F-CPU) and a SINAMICS S120 CU as of
V4.1 SP1


Note
Control for the Safety Integrated functions cannot be routed to the SINAMICS Integrated
of the D4x5 or a CX32 in this constellation.
Additional references
Additional information on configuring Safety Integrated functions can be found in the
SINAMICS S120 Safety Integrated Function Manual
TO Axis Electrical/Hydraulic, External Encoder Function Manual
Available on the Internet at
(http://support.automation.siemens.com/WW/view/en/27585482).
Commissioning (software)
7.21 Migration D445 to D445-1
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 259
7.21 Migration D445 to D445-1
7.21.1 Overview
Characteristics
Due to the following functional improvements, we recommend using SIMOTION D445-1 in
place of SIMOTION D445 for new applications:
An increase of 30% in PLC and motion control performance, dependent upon the
application
Less mounting depth (mounting is possible even without spacers)
New fan/battery module with increased availability thanks to double fan

Figure 7-63 SIMOTION D445-1 control unit
Requirements

Components
Designation Version
Comment
SIMOTION SCOUT as of V4.1 SP2 Full support for SIMOTION D445-1 configuration
Commissioning (software)
7.21 Migration D445 to D445-1
SIMOTION D4x5
260 Commissioning and Hardware Installation Manual, 11/2010
V4.1 SP1 Support of SIMOTION D445-1 configuration, with the constraint that the
D445-1 control unit must be configured as "D445".
SIMOTION D
firmware (kernel)
as of V4.1 SP2 HF3 For information on firmware updates, see Section Performing a firmware
and project update (Page 284).
SIMOTION D445-1
hardware
as of HW version A Order number 6AU1 445-0AA00-0AA1
CompactFlash cards
(CF cards) supported
by SIMOTION D445-
1
- - - 1 GB CF card (6AU1 400-2PA01-0AA0)
1 GB CF card (6AU1 400-2PA00-0AA0)
512 MB CF card (6AU1 400-2NA00-0AA0)
The 32 MB and 64 MB CF cards used previously are no longer supported.
We recommend using 1 GB CF cards.
SIMOTION project
version
V4.1 SP1 Projects from any V4.1 SPx version can run on SIMOTION D445-1 provided
that the CF card has firmware V4.1 SP2 HF3.
7.21.2 Configuration
SCOUT as of V4.1 SP2
SIMOTION D445-1 can be configured with SIMOTION SCOUT as of V4.1 SP2. The D445-1
features "D445" in the "Create new device" dialog as a variant of the CPU type. In the HW
Config module catalog, the D445-1 can be found in the SIMOTION D445 folder under order
number 6AU1 445-0AA00-0AA1.
SCOUT V4.1 SP1
SIMOTION D445-1 can also be configured with SIMOTION SCOUT V4.1 SP1. To do this,
configure a SIMOTION D445- in place of the SIMOTION D445-1 Control Unit.
With SIMOTION SCOUT V4.1 SP1 you can:
Go online with a SIMOTION D445-1
Download the configuration to the SIMOTION D445-1
A D445-1 Control Unit which has been defined with SCOUT V4.1 SP2 as a D445-1 cannot
be configured with SCOUT V4.1 SP1.
7.21.3 Compatibility
As of V4.1 SP2, SIMOTION D445-1 (6AU1 445-0AA00-0AA1) is upwardly compatible for use
with SIMOTION D445 (6AU1 445-0AA00-0AA0).
Commissioning (software)
7.21 Migration D445 to D445-1
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 261
Project Firmware Module
The following compatibility factors must be taken into account for V4.1 SPx:
Device replacement in HW Config
A D445 (6AU1 445-0AA00-0AA0) can be replaced by a D445-1 (6AU1 445-0AA00-0AA1)
of the same version (and vice versa) in HW Config. Configurations are retained in the
case of replacements, as is a CBE30, including configuration.
Common firmware
As of V4.1 SP2 HF3, D4xx firmware can run on all SIMOTION D platforms (D410, D425,
D435, D445, and D445-1).
D445 and D445-1 are project-compatible with firmware as of V4.1 SP2 HF3. This allows a
V4.1 SPx CF card from a D445 to be used in a D445-1 without SCOUT.
Using windows tools and a card reader, copy the "/USER" directory from any V4.1 SPx
version to a CF card with a firmware version V4.1 SP2 HF3; this will enable the project
to run on both a D445 and a D445-1.
A D445-1 project can run on a D445 (and vice versa).
It is possible to go online on a D445-1 using a SCOUT project for D445 (and vice versa).
In this case, it is possible to download from SCOUT and HW Config.
D445 and D445-1 projects on a CF card with a firmware version as of V4.1 SP2 HF3 can
be used in both D445 and D445-1 control units.


Note
A CF card can likewise run on D445 and D445-1 subject the following conditions:
When changing from D445-1 to D445, the lower PLC and motion control performance
is sufficient for the application. If this is not the case, adjustments (e.g. cycle clock
settings) need to be made.
When changing from D445 to D445-1, the application is able to cope with the
increased PLC and motion control performance; i.e. the application is designed in
such a way that shorter running times do not alter the program sequence.
Spacers
SIMOTION D445-1 comes with pre-assembled spacers. In contrast to the D445, these
spacers can be removed from the D445-1 in the same way as from the SIMOTION D425 and
D435. (In the case of the D445, spacers are always required due to the cooling fins on the
module backplane.)
Mounting on the side of the line module
Mounting on the SINAMICS S120 line module using five lateral fixing elements is not
possible with SIMOTION D445-1. SIMOTION D445-1 must always be screwed to the control
cabinet wall.
Interfaces
The interfaces (connectors) of a D445-1 are compatible with a D445.
Fan/battery module
Commissioning (software)
7.21 Migration D445 to D445-1
SIMOTION D4x5
262 Commissioning and Hardware Installation Manual, 11/2010
The standard scope of delivery of SIMOTION D445-1 includes a double fan/battery module
(SIMOTION D445: fan/battery module with single fan).

SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 263
Service and maintenance 8
8.1 Overview
Introduction
It is possible to distinguish between the following scenarios when replacing and updating
components:
Replacing modules (spare part scenario)
General information about the spare parts procedure for SIMOTION D4x5 (Page 267)
Removal and replacement of the SIMOTION D4x5 (Page 268)
Replacing DRIVE-CLiQ components (Page 269)
For information on replacing SIMOTION D4x5 fans, see Section "Replacing the
battery in the fan/battery module" in the SIMOTION D4x5 Manual
Replacing the CompactFlash card (Page 272)
Adapting a project (new device type / device version)
The project needs to be adapted if you want to change the type (e.g. D425 D435) or
version of the SIMOTION device in your existing project.
Creating backup copies (Page 273)
Backing up user data (backup variables) (Page 273)
Upgrading a user project to the new SCOUT version (Page 275)
Platform replacement via XML export/import (Page 276)
Preparing the device replacement (Page 277)
Device replacement in HW Config (Page 279)
Upgrading technology packages (Page 279)
Upgrading the device version of SINAMICS S120 control units (Page 282)
Upgrading a library (Page 283)
Save project, compile and check consistency (Page 284)
Performing a firmware and project update
Upgrading the CF card's boot loader (Page 284)
Update - preparatory measures (Page 285)
Update via IT DIAG (Page 286)
Upgrade via device update tool (upgrading SIMOTION devices) (Page 286)
Service and maintenance
8.1 Overview
SIMOTION D4x5
264 Commissioning and Hardware Installation Manual, 11/2010
Upgrade via CF card (Page 291) with the steps:
Backing up the CF card data (Page 291)
Firmware update via CF card (Page 292)
Upgrading the SINAMICS (Page 293)
Downloading the project to the target system (Page 294)
The upgrade data is generated with the SCOUT function "Start device update tool"
and then transferred to the SIMOTION D4x5 via CF card or IT DIAG file. Upgrading
modules using upgrade data offers the option of downgrading if the upgrade does not
produce the desired result.


Note
Upgrading using the device update tool offers a number of advantages (keeping retain
data, option of downgrading, no license key handling, etc.). We would, therefore,
recommend using this method for firmware and project upgrades.
Please also observe the information on handling the CompactFlash card.
Changing the CompactFlash card (Page 295)
Writing to a CompactFlash card (Page 296)
Formatting the CompactFlash card (Page 297)
Boot loader on the CompactFlash card (Page 297)
Recommended method of handling CF cards (Page 298)
Card reader for CF cards (Page 298)


Note
This document uses the following terms:
Upgrade: Denotes upgrading to a higher version of a component/software
Downgrade: Denotes reverting to a previous version of a component/software
Update: In general terms, denotes the act of bringing a component/software up to date
(or, more specifically, an upgrade or downgrade)
Overview
The exact procedure when replacing or upgrading components depends on various factors.
If a project is upgraded, the procedure depends on the scope of change of the versions.
Change of the SIMOTION main version
Change of the SIMOTION service pack or hotfix version
Change of the PROFINET version
Change of the SINAMICS version
(There are SIMOTION versions that contains several SINAMICS versions for a device)
If another SIMOTION controller is to be used, then the procedure depends on whether a
device or a platform replacement is required.
Service and maintenance
8.1 Overview
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 265
Examples of upgrade scenarios are listed in the following overview table.
They are shown in the columns. The lines list the principle measures that have to be
performed. Whether the measure has to be performed in a specific case, must be decided
project-specifically.
Grayed-out cells mean that a measure is not required.

Note
If the version is changed and the SIMOTION controller replaced at the same time, then all
measures apply; the measures must be performed in the TOP-DOWN sequence according
to the table.

Service and maintenance
8.1 Overview
SIMOTION D4x5
266 Commissioning and Hardware Installation Manual, 11/2010
1)
Downloading the project
to the target system
Upgrading SINAMICS
Firmware update using a
CompactFlash Card
Backup of the CompactFlash
Card data
Selection of the 3 update methods
Upgrade via CompactFlash Card
only possible if the
CompactFlash Card features
a valid frmware version
Update via
device update tool
Update via IT DIAG
Update - preparatory measures
2)
Check if the new device
requires a new bootloader
2)
Check if the new version
requires a new bootloader
Upgrading the boot loader on the
CompactFlash Card
Updating frmware and/or project
Save/compile project; check
consistency
Libraries may be
device-dependent
Libraries are
version-
dependent
Upgrading a library
for external
CUs if required
3)
Upgrading device version of
SINAMICS S120 CUs
Upgrading
technology packages (TP)
Device replacement in HW Confg
Preparing the device replacement
When replacing the platform, the target version is also
determined (= version of the device into which it is imported)
Platform replacement via
XML export/import
Upgrading a user project to the new
SCOUT version
only if required
only if
required
Backing up user data
(backup variables)
Creating backup copies
(project/CF)
D445
(SM150)
D445
(S120)
D445-2 D410
D445-2 C240
D410 PN D410 DP
D4x5-2 D4x5
D455-2 D445-2
V2.6.2
V2.5
PN2.2
PN2.1
V4.1 SP4
V4.1 SP2
V4.2
V4.1
Examples
Platform replacement
via XML export/import
Device replacement via
HW Confg
SINAMICS
version
PROFINET
Version
Service pack or
hotfx version
Main
version
Action/measure
Upgrading a project
Overview of upgrade options
4)
4) 4)
only if required
M
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/
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Replacement of the SIMOTION controller
Activity
afects
Libraries may be
device-dependent
only possible if the
CompactFlash Card features
a valid frmware version
not relevant
5)

1) Alternative: Loading the project to the CF card using a card reader
2) See SW compatibility list (http://support.automation.siemens.com/WW/view/en/18857317)
3) The version of the SINAMICS Integrated and the Controller Extensions are automatically upgraded in HW Config
during a device replacement
4) The technology packages are upgraded automatically. The user can directly specify a TP
5) SINAMICS components are upgraded/downgraded to the component version of the CompactFlash Card. Ensure
that LED codes are observed. Following an upgrade, a POWER ON/OFF is required
Figure 8-1 Upgrade options
Service and maintenance
8.2 Replacing modules (spare part scenario)
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 267
8.2 Replacing modules (spare part scenario)
8.2.1 Parts replacement for SIMOTION D4x5
Replacement rules for SIMOTION D435
In the case of replacement parts, you cannot replace the modules as you wish. You must
comply with the following rules for a SIMOTION D435:
A SIMOTION D435 with the order number 6AU1 435-0AA00-0AA0 can be replaced by a
SIMOTION D435 with the order number 6AU1 435-0AA00-0AA1.
A SIMOTION D435 with the order number 6AU1 435-0AA00-0AA1 cannot be replaced by
a SIMOTION D435 with the order number 6AU1 435-0AA00-0AA0.
SIMOTION D4x5 replacement with firmware downgrade
When replacing a SIMOTION D4x5 V3.2.x with a SIMOTION D4x5 on which a version
V4.0 has previously been run, the following behavior may be observed:
The module signals "Reset requested" (after power-up, the STOP LED flashes yellow at
0.5 Hz) and
It is not possible to go online.
This scenario occurs if the module still contains retain data from a project V4.0 that is not
compatible with a V3.2.x project (buffering of retain data by SuperCap or the battery used).
The following is a description of how you can delete the retain data.
Use of used modules
If a used D4x5 is used for the module replacement, we recommend that the retain data be
deleted on the used D4x5.
Two options are available for this.
Table 8- 1 Options for deleting the retain data
Option Reference to description Notes
Module memory reset See Section SIMOTION D4x5
memory reset (Page 249)
Controller via mode selector
(position "3" MRES).
Is available on all SIMOTION
platforms.
Deleting/restoring non-
volatile data
See Section Deleting/restoring non-
volatile data (Page 317)
Controller via Service switch
(position "1"). Is only available
on SIMOTION D.

Service and maintenance
8.2 Replacing modules (spare part scenario)
SIMOTION D4x5
268 Commissioning and Hardware Installation Manual, 11/2010

NOTICE
With a Power OFF/ON, "Restore factory settings" is performed instead of "Memory reset" in
switch position "3" (MRES) of the mode selector.
Restore factory settings deletes all the project data on the CF card.
To avoid and unintentional/accidental deletion of the project data on the CF card, we
recommend that the retain data be deleted via the Service selector switch.

See also
Setting SIMOTION D4x5 to the default settings (Page 253)
8.2.2 Removal and replacement of the SIMOTION D4x5
Removing the control unit

WARNING
The control unit can be replaced only when the load power supply has been switched off.
Therefore, switch off the power supply now.

How to remove the SIMOTION D4x5:
1. Switch off the power supply.
2. Remove the front cover and remove the CompactFlash card from the plug-in slot.
3. Disconnect the terminal block for the power supply.
4. Disconnect the DRIVE-CLiQ connectors to the SINAMICS S120 modules, the connectors
for the PROFIBUS DP interfaces (X126 and X136), and, if necessary, the Ethernet
connectors to the X120 and X130 interfaces.
5. Disconnect the connectors to the digital inputs and outputs at interfaces X122 and X132.
6. Disconnect any option module which may be inserted (CBE30, TB30).
7. Depending on the mounting method, lift the control unit from the connection to the
SINAMICS S120 drive assembly or remove the mounting screws of the control unit.
Installing a new module
Proceed as follows to install a new SIMOTION D4x5:
1. Remove the front cover from the new control unit.
2. Mount the new control unit.
3. Reconnect all connectors that were removed previously.
Service and maintenance
8.2 Replacing modules (spare part scenario)
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 269
4. Connect the terminal block for the power supply.
5. Reattach the designated shielding for all cables.
6. Reinsert the original CompactFlash card into the plug-in slot.
7. Reattach the front cover and close it.
8. Switch on the power supply. The control unit is immediately ready to operate.
Replacing SIMOTION D4x5 modules without PC/PG
To enable a module replacement without a PG/PC, you must back up the current non-
volatile data to the CF card during operation.
The "_savePersistentMemoryData" system function allows the user program to save the
content of the non-volatile data to the CF card. This ensures that the retain variables and the
absolute encoder position are backed up to the CF card in the event that a spare part is
fitted.
As an additional option, you can back up the non-volatile data by setting the service selector
switch or using IT DIAG; for details, see the section titled Backing up diagnostic data and
non-volatile data (Page 310).

Note
Non-volatile data that is not backed up to the CF card will be lost if a spare part is installed
(in the event of a module defect). (For example, failing to back up the current values of the
retain variables will result in them being lost and reset to their initial values.)
If an absolute encoder overflow occurs after "_savePersistentMemoryData", the actual
position value will no longer be correct once the non-volatile data has been restored. In this
case, homing (absolute encoder adjustment) must be repeated.

See also
Parts replacement for SIMOTION D4x5 (Page 267)
8.2.3 Replacing DRIVE-CLiQ components
Module replacement
DRIVE-CLiQ components can be replaced or reinserted during operation (without POWER
OFF) or when the system is switched off.
Requirement
The affected components are located at the end of the line.
If an infeed is affected, the power units supplied by it do not function.
Service and maintenance
8.2 Replacing modules (spare part scenario)
SIMOTION D4x5
270 Commissioning and Hardware Installation Manual, 11/2010
Procedure for "Removing a component"
1. Deactivate the affected component or the drive object.
2. Remove the DRIVE-CLiQ connector.
3. Remove the supply voltage of the component and uninstall the component.
Procedure for "Installing a component"
1. Install the component and reconnect the supply voltage.
2. Reconnect the DRIVE-CLiQ cable at the same location (port). The cable must have the
same length as the old one.
3. Activate the affected component or drive object.
WARNING

In order to replace this component, the power in the module must be switched off.
Parameters for topology comparator and component replacement
In the expert list, you can use CU parameter p9906 to specify how the electronic rating
plates are compared for all the components of a control unit. The type of comparison can be
changed subsequently for each individual component by using p9907/p9908 or right-clicking
in the topology. All data on the electronic type plate is compared by default.
If p9909 = 1, the serial number and the hardware version of the new replaced component
will be transferred automatically from the actual topology to the target topology and then
saved to non-volatile memory.
For p9909 = 0, serial numbers and hardware versions are not automatically transferred.
Setting p9901 = 1 facilitates spare parts / component replacement without tool support (as of
SINAMICS V2.2). The new serial number of the spare part is automatically transferred from
the actual topology to the setpoint topology and saved in non-volatile memory. Prerequisite
is that the replaced components are of the same type and have the same order number, e.g.
"6SL3055-0AA00-5BA2". The last or last two digits of the order number (depending on the
component type) are not checked, as the HW version, for example, is encoded in these
positions. This mechanism is also applied when several components are replaced.
Modified wiring following module replacement
In the default setting for the topology comparator, modified wiring configurations of
DRIVE-CLiQ components (e.g. cross-exchange) cannot be accepted for safety reasons and
a fault is generated.
Service and maintenance
8.2 Replacing modules (spare part scenario)
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 271
If a cross-exchange of components is required (i.e. existing components are replaced with
other existing components, and no spare parts are used), e.g. for troubleshooting purposes,
the topology comparator must be reduced via parameter p9906, or preferably via
p9907/p9908; alternatively, by right-clicking in the topology.

NOTICE
In this case, incorrect insertion of components is no longer monitored.

Automatic upgrading/downgrading (FW upgrade)
As of SINAMICS firmware version 2.5, the DRIVE-CLiQ components are automatically
upgraded or downgraded to the version of the component firmware on the CF card.
Components that cannot be downgraded to the component firmware version on the CF card
(for example, old firmware on the CF card and new components on which the old firmware
cannot be loaded) retain their firmware version. The resulting firmware version combinations
are always functional.


Note
During an automatic FW upgrade, please read the messages and alarms in the
SIMOTION SCOUT detail window.

The component version can be obtained from the CONTENT.TXT file in the main directory of
the CF card.

Note
The update can take several minutes and its progress is tracked by corresponding
messages appearing in the alarm window of SIMOTION SCOUT.
A firmware update on DRIVE-CLiQ components is indicated by the RDY LED flashing red
and green:
FW update running: RDY LED flashes slowly (0.5 Hz)
FW update complete: RDY LED flashes quickly (2 Hz)
These flashing patterns are also displayed on the yellow RDY LED on the
SIMOTION D/CX32, and indicate that a FW update has been carried out on components
connected to the SIMOTION D/CX32 or that all components have completed the FW update.
Go offline once all the FW updates have been completed. POWER ON the
upgraded/downgraded components.
The upgrade/downgrade function can be deactivated using the p7826 CU parameter in the
expert list.

Service and maintenance
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272 Commissioning and Hardware Installation Manual, 11/2010
Additional references
You can find further information on this topic:
In the SINAMICS S120 Commissioning Manual
SINAMICS S120 Function Manual
8.2.4 Replacing the CompactFlash Card
If spare parts are being used, you must contact the Technical Support Center to convert the
license key of the defective CF card to the new CF card. Proceed as described below to
write your project to the new CF card:
Changing the CompactFlash card (Page 295)
Writing to a CompactFlash card (Page 296)
Detailed information about licensing can be found:
In the SIMOTION SCOUT Configuration Manual
As well as in the FAQ (http://support.automation.siemens.com/WW/view/en/36947932).
8.3 Adapting a project (Updating the project / Replacing the SIMOTION
controller)
8.3.1 Overview
Overview
You will need to adapt the project if you want to replace the type (e.g. D425 -> D435) or
version of the SIMOTION device in your existing project.
Procedure
The exact procedure for project adaptations depends on the scope of the target hardware
and version changes.
An overview of the various applications can be found in Section Service and maintenance at
Overview (Page 263).
Service and maintenance
8.3 Adapting a project (Updating the project / Replacing the SIMOTION controller)
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 273
8.3.2 Creating backup copies (project/CF)
Requirement
Before adapting the project, it is essential that you create the following backup copies:
A backup copy of the project and
A backup copy of the contents of the CF card, see Backing up the CF card data
(Page 291)
8.3.3 Backing up user data (backup variables)
Overview
With the SCOUT functions "Back up variables" and "Restore variables", you have the option
of backing up and restoring data that was changed during operation and only stored in the
runtime system. This is necessary if a SIMOTION platform is changed or a version
upgraded, for example.
The "Back up variables" function creates XML files which are stored in a folder of your
choice.
The following types of data can be backed up:
Retentive global device variables and unit variables, as well as TO retain data (as of
V4.1), located in the SRAM or NVRAM depending on the controller
Data saved with _saveUnitDataSet or _exportUnitDataSet and located on the CF card


Note
When performing an upgrade with a firmware version V4.1, this function is only required
for backing up and restoring unit data sets that have been created using
_saveUnitDataSet.
Retain and unit data (saved with _exportUnitDataSet) remains valid even after a version
upgrade.
Retain data can also be easily backed up to a memory card without the use of
SIMOTION SCOUT. For this purpose, use:
The _savePersistentMemoryData function or
The service selector switch on the SIMOTION D4x5 or IT DIAG
See also Diagnostic data and non-volatile data (Page 310).
Procedure
The backup of the user data must be performed before the upgrade of the SCOUT project.
This is possible for a version upgrade with the "old" SCOUT version or the "new" SCOUT
version.
Service and maintenance
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SIMOTION D4x5
274 Commissioning and Hardware Installation Manual, 11/2010
The following is a description of the procedure with a "new" SCOUT.
1. Open the project.
When opening the project a window appears with a message that the project to be
opened was created with another SCOUT version, as well as a prompt as to whether the
upgrade should be performed.

Figure 8-2 Prompt as to whether the project should be upgraded
2. Confirm the prompt with "OK". The project is upgraded.
3. After the conversion another prompt appears as to whether the project should be opened
write-protected. Confirm this prompt with "Yes" (open write-protected).

Figure 8-3 Prompt as to whether the project should be opened write-protected
Open write-protected means: The project remains consistent. The data is the same in the
controller and in the project. Diagnostic functions (status, trace, etc.) can be executed
directly. The project does not have to be loaded to the controller first.
Go online on the SIMOTION device (in STOP mode) and execute the Save variables
SCOUT function. The retain variables (interface and implementation) and also the user files
(saved with _saveUnitDataSet or _exportUnitDataSet) are saved to the PG/PC.
The project must then be closed.
If you are using a different PC or PG than that configured for the controller, an online
connection is not possible.
Update the PG/PC assignment for this.
You can go directly to the PG/PC assignment via the button.
The SCOUT project can then be opened again write-protected --- online connection is now
possible.
Additional references
For further information, see the SIMOTION SCOUT Configuration Manual.
Service and maintenance
8.3 Adapting a project (Updating the project / Replacing the SIMOTION controller)
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 275
8.3.4 Upgrading a user project to the new SCOUT version
Requirement
It is essential that a backup copy be made of the original project before the upgrade,
because the data storage of the project is also upgraded during the upgrade. This ensures
that you can always return to the original project if the upgrade fails (power interruptions,
unexpected faults, maloperation, etc.).
Procedure
1. When opening the project a window appears with a message that the project to be
opened was created with another SCOUT version, as well as a prompt as to whether the
upgrade should be performed.
Confirm the prompt with "OK".

Figure 8-4 Prompt as to whether the project should be upgraded
2. After the conversion another prompt appears as to whether the project should be opened
write-protected. Confirm this prompt with "No" for a version upgrade (do not open write-
protected).

Figure 8-5 Prompt as to whether the project should be opened write-protected
Do not open write-protected means:
The project can be edited. The data in the controller and in the project is not consistent after
going online. Diagnostic functions cannot be executed directly. The project must be loaded
to the controller first.
Service and maintenance
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SIMOTION D4x5
276 Commissioning and Hardware Installation Manual, 11/2010
Open write-protected:
The project remains consistent. The data is the same in the controller and in the project.
Diagnostic functions (status, trace, etc.) can be executed directly. The project does not have
to be loaded to the controller first.

Note
A project that was last edited with a higher SCOUT version cannot be opened by a SCOUT
with a lower version. However, the project with the more current SCOUT version can first be
converted to the required software version (command: "Project" > "Save in old project
format"). The project can then be opened with the lower SCOUT version. However, debug
information (e.g. for program status) is no longer available.

8.3.5 Platform replacement via XML export/import
Overview
A platform replacement is always required when an existing project is to be used for another
SIMOTION platform. The platform replacement is always performed via an
XML export/import.
The following devices can be interchanged via a platform replacement:
Replacement between SIMOTION C, P and D (e.g. C240 D445-2 DP/PN)
Replacement between D410 and D4x5/D4x5-2 (e.g. D410 D445-2 DP/PN)
Replacement between SIMOTION D (SINAMICS S120 Integrated) SIMOTION D
(SINAMICS SM150 Integrated)
Platform replacement during project downgrades:
It is not possible to downgrade to a lower SINAMICS version. However, it is possible to
transfer project data by means of an XML export/import.
Preparations
Before the platform replacement can be performed, preliminary work may be necessary in
the existing project.
If a D4x5 is to be imported into a D410, then only the permitted quantity structure of the
D410 may be configured in the D4x5. This applies for all components, e.g. not only an
infeed, but also the permissible power units.
A D4x5 with CU adapter and PM340 can be imported into a D410 when the CU adapter is
connected to port 0. Otherwise, the topology will be destroyed.
Generally, the success of an import always also depends on the specific configurations of
the drive units, and whether the configuration is possible for the device to which the import is
to be performed. Also note any error messages that may occur.
Service and maintenance
8.3 Adapting a project (Updating the project / Replacing the SIMOTION controller)
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 277
Procedure
Proceed as follows:
1. In the project navigator of SIMOTION SCOUT, right-click the SIMOTION controller that is
to be replaced.
Select "Expert" > "Save project and export object" in the context menu.
"Save project and export object" exports selected data of the selected object in XML
format. This data export can then be reimported into other projects. The entire project is
not exported, only the data of the selected object (e.g. only the D4x5 or only the
SINAMICS Integrated)
2. Specify the desired path and start the XML export.
3. When the export has been performed error-free, delete the device from the project and
confirm the prompt.
4. Insert the desired platform as new device in the project navigator of SIMOTION SCOUT.
With the selection of the device, you also define the SIMOTION version, and with a
SIMOTION D, also the SINAMICS version.
5. Import the data of the original platform into the new device. To do this, right-click the new
device and select "Expert" > "Import object" in the context menu.
6. Select the location where the XML export data is to be stored and start the import.
Confirm the prompt to continue with the import.
Confirm the message with regard to the import of a "non-compatible type" with "OK".
8.3.6 Preparing the device replacement
Overview
The device replacement process differs from the platform replacement process in that it is
really easy to accept project data during device replacement.
The device replacement is performed via HW Config, whereas an XML export/import is
required for a platform replacement.
A device replacement is only possible within SIMOTION D.
The following devices can be interchanged:
Replacement between different performance classes (e.g. D425 D435)
Replacement between generations (D4x5 D4x5-2)
Replacement between variants (D410 DP D410 PN)
Replacement between SIMOTION, SINAMICS and/or PROFINET version (e.g.
D425 V4.1 - PN V2.1 SINAMICS S120 V2.5 D425 V4.2 - PN V2.2 SINAMICS S120
V2.6.2).
One SIMOTION D can only be replaced with another SIMOTION D if the SINAMICS version
involved is the same or higher. It is not possible to downgrade to a lower SINAMICS version.
Service and maintenance
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SIMOTION D4x5
278 Commissioning and Hardware Installation Manual, 11/2010
Preparation
Before the device replacement can be performed, it is recommended that preliminary work
be performed in the existing project. The existing project must be adapted so that it can be
mapped to the new device during the device replacement.
Examples:
1. Number of DRIVE-CLiQ interfaces
If the replacement is to a device with fewer DRIVE-CLiQ interfaces, then the ports that
are no longer available must be rewired before the device replacement (double-click
"Topology" in the project navigator). Components on DRIVE-CLiQ ports that are no
longer available are moved to the component archive during the device replacement.
Example:
Replacement of D445-1 (six DRIVE-CLiQ ports) with D435 (four DRIVE-CLiQ ports)
ports X104 and X105 are no longer available.
Procedure for CX32
If a CX32 is to be moved to another port, this is only possible via HW Config. Note the
dependency between "DRIVE-CLiQ port" and "Address on the PROFIBUS Integrated" in
Section Preparing for configuration (Page 176).
2. Number of CX32s
If the replacement is with a D4x5 that only supports a small number of CX32 modules,
then a device replacement in HW Config is not possible.
In this case, the CX32 must be replaced by a SINAMICS S120 CU320/CU320-2.
3. PROFINET interface
If a D4x5 with CBE30 is replaced by a D4x5-2 DP/PN with onboard PROFINET interface,
then the number of PROFINET ports is reduced from four to three.
Components on port 4 have to be rewired
4. Retrofitting to V4.1
If a SIMOTION D4x5 is downgraded by replacing a device in HW Config, you must take
into account the fact that symbolic assignments are only available as of version V4.2. If
symbolic assignments are used and, for example, a D4x5 V4.2/SINAMICS V2.6.2 is
downgraded to D4x5 V4.1/SINAMICS V2.6.2, "communication for symbolic assignment"
must be set up prior to replacing the device in HW Config. This sets up the required
addresses.
See also Section Communication for symbolic assignment setup (Page 216).
TIP for synchronous grouping
If you use device-dependent ST libraries, then the upgrade can be accelerated through the
following procedure:
1. Upgrade the device version for all devices that participate in the synchronous grouping in
the ST libraries (example: Change D445 V4.1 to D445-2 V4.2).
See also Section Upgrading a library (Page 283).
2. Save the project and close it in SIMOTION SCOUT.
3. Perform the module replacement for all devices of the synchronous grouping in
HW Config for this project and then save.
4. Open the project in SIMOTION SCOUT.
The entire synchronous grouping is now completely upgraded.
Service and maintenance
8.3 Adapting a project (Updating the project / Replacing the SIMOTION controller)
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 279
8.3.7 Device replacement in HW Config
Procedure
1. Double-click the SIMOTION device to be replaced in the project navigator in
SIMOTION SCOUT. HW Config opens.
2. Open the "SIMOTION Drive-based" folder in the hardware catalog.


Note
SIMOTION D is modeled as a compact device in HW Config. When modules are being
replaced, this means the new module must be moved to the header of the module rack
shown and not to slot 2. Please make sure that you do not delete the D4x5 rack!
When you move the new module to the rack header using drag-and-drop, the old module
will be replaced. Alternatively, you can:
Select the rack header and double-click the new module in the module catalog to
replace the previous module, or
Right-click the rack header and select "Replace Object"
3. Move the new module to the top field of the module rack using drag-and-drop.
4. Confirm the dialog that appears with "Yes" to replace the SIMOTION device. The module
is replaced.
5. Accept the changes made to the hardware configuration with "Station" > "Save and
compile".
6. Close HW Config.


Note
As of SIMOTION SCOUT V4.2, the following actions are performed automatically by the
engineering system during the module replacement (if required):
Upgrade of the technology packages (TPs)
Automatic upgrade of the SINAMICS Integrated
Automatic upgrade of all connected CX32
The upgraded data is transferred to the project and the entire project saved.
If the module hardware changes (e.g. a D425 is replaced with a D435), proceed as
described in Section Removal and replacement of the SIMOTION D4x5 (Page 268).
8.3.8 Upgrading technology packages
Overview
The SIMOTION technology packages (e.g. TP CAM, TP PATH, DCBlib) are available in
various versions.
Service and maintenance
8.3 Adapting a project (Updating the project / Replacing the SIMOTION controller)
SIMOTION D4x5
280 Commissioning and Hardware Installation Manual, 11/2010
You can only use the functions of the technology objects selected if the technology objects
are available in the target system. You can select the technology packages and their version
for each SIMOTION device. Each version of SIMOTION SCOUT has a kernel (FW version)
for the SIMOTION CPU and an appropriate technology package.
TPs during upgrades
Device replacement (in HW Config), platform replacement (XML export/import), or even
upgrades may cause versions of SIMOTION technology packages (TPs), which are
assigned to individual technology objects (TOs), to change.
The TP version may change when the main version is changed.
The TP version depends on the relevant main version in all cases; it may, however,
remain unchanged through a number of main versions.
If service packs and hotfixes are installed, there may even be a selection of TP product
versions available for the same TP version
The TP version is automatically upgraded during device replacement (in HW Config). If the
TP version changes and there are several product versions available for the new TP version,
the latest product version is set automatically. If another product version is preferred, this
must be set manually (e.g. selection of V 4.1.5.3).
With a platform replacement (XML export/import), the required technology package along
with the TP version and, if necessary, the product version have to be selected manually after
the import.
When a SIMOTION CPU is inserted, the TP CAM (latest TP version and product version) is
preset per default.
Special displays in the "version" field
"Select" means that no TP product version has been selected; this state occurs when
older projects, in which the selection of a specific product version was not supported, are
upgraded. If the project is loaded to the CPU without making a selection, the latest
available technology package is loaded automatically.
"---" means that no version can be determined (e.g. for the TP DCBlib or for older CPU
versions < V4.1). If no version can be determined, you must select "---".
Service and maintenance
8.3 Adapting a project (Updating the project / Replacing the SIMOTION controller)
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 281
Selecting the TP product version
The desired technology package is selected with fine granularity in SIMOTION SCOUT at
"Target device" > "Select technology packages ...".

Figure 8-6 Select technology packages

Note
Device diagnostics can provide information on which technology package product version
has been loaded to a CPU.

Loading technology packages to the target device
Technology packages are only loaded to the target device if no technology package has
been loaded so far or if "Load to file system" is executed.
If a technology package version changes, the technology package must be explicitly
reloaded to the target device. Proceed as follows:
1. Select "Download project to target system" in SIMOTION SCOUT.
2. Select the "Replace product versions of the technology packages" option and confirm
with "OK".
For further information, please refer to the online help for SIMOTION SCOUT.
Service and maintenance
8.3 Adapting a project (Updating the project / Replacing the SIMOTION controller)
SIMOTION D4x5
282 Commissioning and Hardware Installation Manual, 11/2010
See also
Deleting user data from CF card (Page 252)
8.3.9 Upgrading the device version of SINAMICS S120 control units
Overview
You can upgrade the device versions of SINAMICS S120 control units that are connected to
the SIMOTION D via PROFIBUS or PROFINET in the SIMOTION SCOUT. The SINAMICS
version can only ever be upgraded in a project; it cannot be downgraded.

Note
During the device replacement in HW Config, the SINAMICS version
Of the SINAMICS Integrated of the SIMOTION D4x5 as well as
The connected CX32 controller extensions
are also upgraded automatically.

A CX32 always has the same SINAMICS version as the SINAMICS Integrated. During the
module replacement in HW Config, the SIMOTION and the SINAMICS version is always
defined with the selection of a D4x5 module.
If a SINAMICS S120 control unit is connected via PROFIBUS or PROFINET, the SINAMICS
version can be selected independently of the SINAMICS Integrated version.
Service and maintenance
8.3 Adapting a project (Updating the project / Replacing the SIMOTION controller)
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 283
Procedure
To upgrade a SINAMICS drive unit:
1. Right-click the relevant device, e.g. the SINAMICS S120 CU320-2 DP.
2. Select "Target device" > "Upgrade device version/characteristic" in the context menu.
The "Upgrade Device Version/Characteristic" dialog box is displayed, listing all available
firmware versions.

Figure 8-7 Upgrading the device version
3. Select the desired device version/characteristic and click "Upgrade".
This upgrades the SINAMICS S120 control unit.
8.3.10 Upgrading a library
Depending on the configured properties of the libraries used in the project (device-
dependent or device-independent), an upgrade of the libraries may be required if the
SIMOTION device or the device version changes.
1. Open the LIBRARY directory in the project navigator.
2. Select a library, right-click to open the context menu, and select "Properties...."
3. Select the "TPs/TOs" tab in the "Properties" window.
4. Select the SIMOTION device and the technology packages for which the library is to be
valid.
5. Close the dialog with "OK".


Note
Please also observe the information on device-dependencies in the SIMOTION SCOUT
online help.

Service and maintenance
8.4 Performing a firmware and project update
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284 Commissioning and Hardware Installation Manual, 11/2010
8.3.11 Save project, compile and check consistency
Procedure
1. Execute "Save and recompile all" ("Project" > "Save and recompile all" menu).
2. Then perform a consistency check ("Project" > "Check consistency" menu).
3. If error messages occur, correct these and repeat the operation.


Note
Note the difference between
"Save and recompile all" and
"Save and compile changes"

Save and recompile all
All sources of the entire project are recompiled with this command.
The command is suitable if you are quite sure that all the old data from older SCOUT
versions should be removed and replaced with new compilation results.
Use this command if you specifically want to convert a project from an earlier SCOUT
version to a newer version. In this way, you take over all error corrections and optimizations.
Save and compile changes
On this command, the whole project is searched for changes. Therefore only the changes
are compiled. Use this command for day-to-day operations within a SCOUT version.

8.4 Performing a firmware and project update
8.4.1 Upgrading the CompactFlash Card's boot loader
Upgrading the SIMOTION D may also render it necessary to upgrade the boot loader of the
CompactFlash card.
Detailed information on the compatibility relationships for the CF card, boot loader version,
SIMOTION D hardware and SIMOTION firmware version can be found in the software
compatibility list. This list is available both in the documentation supplied on the SIMOTION
SCOUT DVD (\1_Important\English\Compatibility\...) and on the Internet at
(http://support.automation.siemens.com/WW/view/en/18857317).
Service and maintenance
8.4 Performing a firmware and project update
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 285
8.4.2 Update - preparatory measures
Upgrading the SIMOTION D
The actions described in this section also apply to downgrading to an older version.
Various options are available for performing a firmware and/or project upgrade on the
SIMOTION D.
Update via IT DIAG (Page 286)
Upgrade via device update tool (upgrading SIMOTION devices) (Page 286)
Upgrade via CF card (Page 291)


Note
Upgrading using the device update tool offers a number of advantages (keeping retain
data, option of downgrading, no license key handling, etc.).
We therefore recommend using this method for firmware and/or project upgrades.
Requirement (firmware upgrade)
You can find the latest firmware for SIMOTION D:
On the SIMOTION SCOUT DVDs (e.g. at ...\3_D4xx\Firmware\V4.2\....)
at Internet address (http://support.automation.siemens.com/WW/view/en/31045047)
Upgrading the SIMOTION D automatically upgrades the firmware of all connected
SINAMICS DRIVE-CLiQ components.

Note
Observe the information in the the Read Me files and the upgrade instructions included in the
scope of delivery of new SIMOTION versions.
Use only CF cards that have been released for SIMOTION D and have an appropriate and
correct boot loader version.

You can find the compatibility relationships in the SIMOTION SCOUT Add-Ons "software
products" compatibility list, as well as at Internet address
(http://support.automation.siemens.com/WW/view/en/18857317).

NOTICE
The upgrade operation deletes all project data and parameters from the CF card!

Service and maintenance
8.4 Performing a firmware and project update
SIMOTION D4x5
286 Commissioning and Hardware Installation Manual, 11/2010
Requirement (project upgrade)
You have upgraded your project and, if necessary, adapted the device type and device
version, see Section Adapting a project (Updating the project / Replacing the SIMOTION
controller) (Page 272).
8.4.3 Update via IT DIAG
The SIMOTION D features an integrated Web server.
In addition to customized Web sites and comprehensive device/diagnostic information, one
of the options that IT DIAG offers is performing firmware and project upgrades using a
standard PC with Internet Explorer.
As of firmware version V4.2, it is no longer necessary to purchase licenses for SIMOTION IT
DIAG and SIMOTION OPC-XML.

Note
D410, D4x5, and D4xx firmware ZIP archives are available for SIMOTION D. The firmware in
D4xx archives will run on SIMOTION D410 and SIMOTION D4x5. However, it cannot be
loaded with IT DIAG if the CF card contains a firmware version < V4.1 SP2. In this case you
should use the D410 or D4x5 firmware archive.

Detailed information can be found in the
SIMOTION IT Ethernet-Based HMI and Diagnostic Functions Diagnostics Manual.

See also
Adapting a project (Updating the project / Replacing the SIMOTION controller) (Page 272)
8.4.4 Upgrade via device update tool (upgrading SIMOTION devices)
Overview
As of SIMOTION V4.1 SP2, SIMOTION D control units and projects can be upgraded using
previously created upgrade data.
Performing an upgrade using upgrade data has the following advantages:
User-friendly creation of upgrade data via SIMOTION SCOUT with the aid of a wizard (at
the machine manufacturer's site)
SIMOTION devices can be upgraded by the machine operator without the SIMOTION
SCOUT Engineering System.
The machine manufacturer can conveniently send upgrade data via e-mail or post to the
machine operator.
Service and maintenance
8.4 Performing a firmware and project update
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 287
There is no need to use license keys, as licenses are retained.
Retain data and unit data is retained when upgrades are performed, even across
versions.
An upgrade which has been imported can be discarded again, and the previous
configuration restored.
You can update either a single SIMOTION device or multiple devices from one or more
SIMOTION projects.
It is possible to upgrade parts of a configuration only (e.g. Technology Packages only,
firmware only, project only, etc.).
Upgrade data is created by the application engineer at the machine manufacturer's premises
using SIMOTION SCOUT. The upgrade data can then be handled flexibly depending on both
the SIMOTION device in question (SIMOTION C, D, or P) and the customer requirements:
Creating upgrade data and then copying it to a storage or upgrade medium:
CF card
USB stick or
IT DIAG file
Alternatively, the upgrade data can be created and stored in an archive on the PC, with a
view to importing it to an upgrade medium suitable for SIMOTION devices at a later point.
The process of importing the data to an upgrade medium can be performed at the
machine manufacturer's premises; alternatively, if the upgrade archive has been
transferred to the machine operator, the service engineer can do this on-site.
The service engineer imports the upgrade data on an operator-guided basis (without any
involvement by the application engineer) to the SIMOTION device(s), and upgrades the
SIMOTION devices in the process (SIMOTION SCOUT is not required on-site).
The following describes how to upgrade a SIMOTION D with a USB stick. This assumes you
have a USB stick containing the appropriate upgrade data.
Requirement
You have a USB stick containing the upgrade data.
You have a SIMOTION D module with the required HW version.
The following hardware is required in order to upgrade a SIMOTION D4x5 using a USB stick:
Table 8- 2 Hardware required for USB stick upgrades
Module Order No. Minimum hardware release
required
1)

SIMOTION D425 6AU1 425-0AA00-0AA0F F
2)

SIMOTION D435 6AU1 435-0AA00-0AA0 Upgrade via USB stick not
supported
SIMOTION D435 6AU1 435-0AA00-0AA1 F
2)

Service and maintenance
8.4 Performing a firmware and project update
SIMOTION D4x5
288 Commissioning and Hardware Installation Manual, 11/2010
Module Order No. Minimum hardware release
required
1)

SIMOTION D445 6AU1 445-0AA00-0AA0 A
SIMOTION D445-1 6AU1 445-0AA00-0AA1 A
1)
The HW version is listed on the SIMOTION D type plates.
2)
Modules with HW version C to E can be upgraded (upgrade to BIOS V00.00.04.00).
Required BIOS version
With SIMOTION D425/D435, a BIOS version of at least V00.00.04.00 is required for USB
support. Modules as of hardware version "F" are supplied with a corresponding BIOS
version. A BIOS upgrade can be conducted on SIMOTION D425/D435 modules with a BIOS
version < V00.00.04.00. The BIOS version is shown in the device diagnostics in SIMOTION
SCOUT.
Proceed as follows to do this:
1. Switch the module off and insert a CF card with SIMOTION D4x5 firmware version V4.1
SP2 or higher.
2. Turn the left rotary switch (SIM/NCK) to switch position C.
3. Switch the module on and wait until the BIOS upgrade has been carried out. The BIOS
upgrade is completed when the 7-segment- display shows "5" (RUN LED flashes green at
2 Hz, RDY LED lights up red).
4. Switch the module off and reset the rotary switch to "0".
NOTICE

A BIOS upgrade must not be interrupted under any circumstances. With this in mind, do
not switch the module off until the BIOS upgrade is complete. A damaged BIOS will
require expensive repair work to be carried out at the plant.
5. A successful BIOS upgrade is also displayed in the diagnostic buffer at the next power-
up.
Procedure
When using a USB stick to perform an upgrade, proceed as follows:
1. Check the position of the service selector switch (left rotary switch SIM/NCK). The switch
position must be at "0".
2. Insert the USB stick into one of the two USB interfaces on the activated D4x5 (only one
USB stick may be inserted).
3. Switch the device OFF/ON or reset it using the RESET button.
Service and maintenance
8.4 Performing a firmware and project update
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 289
4. SIMOTION D4x5 will now begin copying the data from the USB stick to the CF card. The
copying procedure begins with some LED status changes until finally a yellow/green
flashing RDY LED is displayed (0.5 Hz). In the end phase of the upgrade, the RDY LED
has longer steady green or yellow phases (< 10 s).
Once copying is complete, the RDY LED will change to
"Steady green" (only when the RDY-LED is constantly green for > 10 s, has the
copying procedure been completed successfully)
"Steady red" if copying was not successful
5. Switch the D4x5 off and remove the USB stick.
6. Switch the D4x5 back on. The D4x5 now begins with the actual upgrade. The SF LED
flashes green (0.5 Hz) during the upgrade. The procedure can take several minutes.
7. Observe the green flashing of the SF LED.
As soon as the upgrade procedure has been completed successfully, the SF LED
goes out.
The device then boots up automatically in the upgraded configuration (SF LED display
then depends on the operating mode of the device).
If the upgrade procedure was not successful, the SF LED flickers red (10 Hz).
If the upgrade has not been successful "from the point of view of the application" (for
example, the machine is not behaving as desired), it can be undone as follows:
1. Switch the D4x5 off.
2. Turn the left rotary switch (SIM/NCK) to position "B".
3. Switch the D4x5 back on.
The system restores the data saved during the upgrade. The data from the upgrade
process will be deleted.
Service and maintenance
8.4 Performing a firmware and project update
SIMOTION D4x5
290 Commissioning and Hardware Installation Manual, 11/2010
4. The restoration is indicated by a green flashing SF LED (0.5 Hz) and can take several
minutes. When the flashing code is displayed, immediately reset the Service selector
switch to "0".
5. Observe the flashing of the SF LED.
As soon as the restore procedure has been completed successfully, the SF LED goes
out.
The device then boots up automatically in the restored configuration. (SF LED display
then depends on the respective mode of the device.)
If the restore procedure was not successful, the SF LED flickers red (10 Hz).


Note
If the Service selector switch is not reset or not reset in good time to "0", this results in
fault state "Service selector switch is still set to restore" (SF LED flickers red at 10 Hz).
In this case, switch the D4x5 off, reset the Service selector switch and switch the D4x5
on again. If the restoration was otherwise successful, the D4x5 boots up with the
restored configuration.


Note
In the case of a CPU upgrade via USB stick the SIMOTION D4x5 is booted from the
USB stick. A bootable USB stick must, therefore, be used. Due to the rapid
developments within the market for USB sticks, it is not possible to recommend any
specific devices. SIMATIC USB sticks are an exception to this rule. For more
information, see Available on the Internet at
(http://support.automation.siemens.com/WW/view/en/32580863).


Note
If the firmware for SIMOTION D is being upgraded or downgraded, the component
firmware will also be upgraded or downgraded automatically depending on the
firmware version on the CF card and the firmware version on the SINAMICS
components (DRIVE-CLiQ components, CBE30, PM340, etc.).
The upgrade procedure can take several minutes and is indicated by LED displays.
A firmware update on DRIVE-CLiQ components is indicated by the RDY LED flashing
red and green:
FW upgrade running: RDY LED flashing slowly (0.5 Hz)
FW upgrade complete: RDY LED flashing quickly (2 Hz)
These flashing patterns are also displayed on the yellow RDY LED on the
SIMOTION D/CX32, and indicate that a FW update has been carried out on
components connected to the SIMOTION D/CX32 or that all components have
completed the FW update.
Once the FW upgrade is complete on all components, the components that have been
upgraded/downgraded must be powered up.
Requirement
You have a USB stick containing the upgrade data.
Service and maintenance
8.4 Performing a firmware and project update
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 291
Additional references
Detailed information on upgrading devices can be found in the
Upgrading SIMOTION Devices Operating Instructions.
8.4.5 Upgrade via CF card
8.4.5.1 Backup of the CF card data
Backing up licenses, retain data, and user data
Prior to upgrading/downgrading, as a precaution we would generally recommend backing up
the entire content of the CF card to the PC/PG using the card adapter and Windows
Explorer.
How you should proceed when it comes to backing up and subsequently restoring data on
the CF card depends on whether licenses and/or other retain data and user data which will
be required again after the upgrade/downgrade are located on the CF card.
Scenario 1: If the CF card contains no licenses and no retain data or user data which will be required
after the upgrade/downgrade
You do not need to take any steps in this case. Delete the content of the CF card and
upgrade the firmware as described.
Scenario 2: If the CF card contains licenses (e.g. axis licenses)
Before loading the new firmware, back up the "KEYS" directory to your PC. This can then be
copied back to the CF card once you have installed the new firmware.

Note
The license key is stored in the "KEYS" directory on the CF card. When the
SIMOTION device starts up for the first time (as of firmware version V4.1), the license key is
saved in the boot sector of the CF card.
A license key saved in the boot sector cannot be deleted by means of a user operation; nor
can it be deleted by formatting the CF card or rewriting the boot loader.
If the Keys.txt file is no longer present on the CF card (because the "KEYS" directory has
been deleted, for example), it will be written again from the boot sector to the "KEYS"
directory while the SIMOTION device is starting up. The license key can be changed at any
time (by relicensing, for example). When the device is next started up, the license key will be
saved in the boot sector again.

In the event of the loss of a license key, a copy can be obtained via the Web License
Manager at the following Internet address (http://www.siemens.com/automation/license).
You will need the HW serial number printed on the CF card. In the Web License Manager,
you have the option of displaying the associated license key.
Service and maintenance
8.4 Performing a firmware and project update
SIMOTION D4x5
292 Commissioning and Hardware Installation Manual, 11/2010
Scenario 3: If the CF card contains retain data / user data which will be required after the
upgrade/downgrade
If you are using your application to back up data to the CF card, you must back this up
before upgrading the new firmware.
Example:
Backing up retain data (non-volatile data saved with _savePersistentMemoryData):
user\simotion\pmemory.xml
Backing up IT DIAG user files, settings (e.g. trace.xml), task trace data, log files, and
Java files (classes, archives, user file system, etc.), stored in the following directories:
user\simotion\hmicfg
user\simotion\hmi
Backing up configuration data for modular machines in conjunction with the
_activateConfiguration system function, stored in the following directory:
install\simotion
Backing up unit data (data saved on the CF card using
_saveUnitDataSet/_exportUnitDataSet), stored in the following directory:
user\simotion\user dir\<unitname>


Note
When a version is changed, you must use the "Back up variables" function to back up
data saved using _saveUnitDataSet or _exportUnitDataSet in a way that is not
dependent on the version. You then have the option of restoring them using "Restore
variables".
When performing an upgrade with a firmware version V4.1, these two functions are
only required for backing up and restoring unit data sets that have been created using
_saveUnitDataSet.
Retain and unit data (saved with _exportUnitDataSet) remains valid even after a
version upgrade.

8.4.5.2 Firmware upgrade via CF card
Procedure
Proceed as follows to perform the upgrade:
1. Switch off the power supply to the D4x5.
2. Remove the CF card from the SIMOTION D4x5 and insert it into the CF card adapter on
your PC.
3. Open Windows Explorer. The CF card must be visible as a removable data carrier in the
Windows Explorer under an arbitrary drive letter.
Service and maintenance
8.4 Performing a firmware and project update
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 293
4. If necessary, back up the licenses, retain data, and user data on the CF card to your PC
(see Section Backup of the CF card data (Page 291)).
5. Delete all the data from the CF card.
6. Unzip the firmware file to the CF card using a ZIP file utility such as WinZip. Always
maintain the file structure when setting up the decompression tool.
7. Copy the data saved in step 4 back to the appropriate folder structure on the CF card.
8. Remove the CF card from the CF card adapter on your PG/PC.
9. Insert the CF card into the D4x5.
10. Switch on the power supply for the D4x5. The new firmware is loaded from the CF card to
the SIMOTION D4x5.
8.4.5.3 Upgrading SINAMICS
Depending on the settings, the SINAMICS components are also automatically upgraded to
the component version of the CF card with a firmware upgrade of the SIMOTION D.
The component version can be obtained from the CONTENT.TXT file in the main directory of
the CF card.
Upgrading the firmware of SINAMICS components automatically
When starting up, the system automatically upgrades or downgrades all DRIVE-CLiQ
components to the version of the component firmware on the CF card. Components that
cannot be downgraded to the component firmware version on the CF card (e.g. old firmware
on the CF card and new components to which the old firmware cannot be loaded) retain their
firmware version. The resulting firmware version combinations are always functional.

Note
The components' firmware is upgraded or downgraded automatically based on the FW
version on the CF card and the FW version on the SINAMICS components (DRIVE-CLiQ
components, CBE30, PM340, etc.).
The update can take several minutes and its progress is tracked by corresponding
messages appearing in the alarm window of SIMOTION SCOUT.
A firmware update on DRIVE-CLiQ components is indicated by the RDY LED flashing red
and green:
FW upgrade running: RDY LED flashes slowly (0.5 Hz)
FW upgrade complete: RDY LED flashes quickly (2 Hz)
These flashing patterns are also displayed on the yellow RDY LED on the
SIMOTION D/CX32, and indicate that a FW update has been carried out on components
connected to the SIMOTION D/CX32 or that all components have completed the FW update.
Go offline once all the FW upgrades have been completed. POWER ON the
upgraded/downgraded components.

Service and maintenance
8.4 Performing a firmware and project update
SIMOTION D4x5
294 Commissioning and Hardware Installation Manual, 11/2010
Upgrading the firmware of the SINAMICS components
The SINAMICS components' firmware is upgraded automatically, depending on the setting of
parameter p7826.
p7826 = 0: Upgrade/downgrade deactivated (factory setting)
p7826 = 1: Upgrade and downgrade
p7826 = 2: Upgrade only
CAUTION

The automatic FW upgrade via p7826 = 1 (upgrade and downgrade) must not be
deactivated when using Safety Integrated.
If you are upgrading the firmware manually, proceed as follows:
1. Select the SINAMICS component in the project navigator, e.g. SINAMICS Integrated.
2. Double-click "Overview" in the project navigator.
The "SINAMICS_Integrated - Overview" dialog box opens with a list of available drive
objects.
3. Click "Version overview" to open the list of connected SINAMICS components.
4. Go online and select the devices whose firmware you wish to upgrade.
The list displays the current firmware version of the devices.
5. Click "Firmware upgrade" to download the new firmware to the devices. To do so, you
must select all components whose firmware is to be upgraded.
6. When the firmware upgrade is complete, switch the 24 V power supply off and back on
again. The device is now ready for operation.


Note
The SINAMICS components must be configured for a firmware upgrade to take place.
The firmware cannot be upgraded if the components have not been configured.
You can also upgrade the firmware using the expert list. See the SINAMICS S120
Commissioning Manual for a description of how to do this.

8.4.5.4 Loading a project to the target system
Once all the changes required for upgrading your project have been made, you must
download the project to the SIMOTION D4x5. You have recompiled the project and checked
it for consistency. See Section Saving the project and checking the consistency (Page 284).
Requirement
The firmware required is located on the CF card; for information, see Section Firmware
upgrade using a CF card.
Service and maintenance
8.5 SIMOTION Compact Flash card
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 295
Procedure
1. Save and compile the project.
2. Click "Connect to selected target systems" to establish a connection to the target system.
3. Execute "Download project to target system" and then "Copy RAM to ROM" to download
the upgraded project to the CF card as well.
4. Because of the automatic follow-up configuration in the SINAMICS Integrated drive, you
must now execute "Load CPU / drive unit to PG".
5. Save the project.


Note
When upgrading SINAMICS drive units (e.g. SINAMICS Integrated) only the p
parameters (setting parameters) are loaded into the upgraded project. The r parameters
(monitoring parameters) are not loaded. The r parameters in the drive unit are derived or
calculated from an automatic subsequent parameterization and must therefore be
uploaded to the project. To do this, execute "Load CPU/drive unit to PG". If the upload is
not performed, this can lead to inconsistencies in the drive parameterization dialog boxes.
8.5 SIMOTION Compact Flash card
8.5.1 Changing the CompactFlash Card
Requirement

CAUTION
The CF card may only be unplugged and plugged in when the system is switched off (zero
current)! The SIMOTION D4x5 is in a de-energized state when all the LEDs are OFF.

Procedure
To change the CF card, proceed as follows:
1. Switch off the power supply.
2. Remove the CF card from the plug-in slot of the control unit.
Service and maintenance
8.5 SIMOTION Compact Flash card
SIMOTION D4x5
296 Commissioning and Hardware Installation Manual, 11/2010
3. Gently insert the new CF card into the empty plug-in slot until it clicks into place. The
direction of insertion of the CF card is indicated by an arrow located on both the plug-in
slot and the CF card.
When properly installed, the card does not extend beyond the housing of the SIMOTION
D4x5.
4. Switch the power supply on again.
8.5.2 Writing to the the CompactFlash card
Overview
You can write to the CF card by:
Writing to a CF card inserted into a SIMOTION D
This function requires the connection to be established between the PG/PC and the
module.
Writing to a CF card without a SIMOTION D module
For this function, you need a CF card adapter.


Note
The CF card always comes formatted. It contains the SIMOTION Kernel (SIMOTION D
firmware).
To ensure that the CF card functions properly, the card must not be repartitioned.
Writing to a CF card inserted into a SIMOTION D
The CF card can be used to store technology packages and user data (programs,
configuration data and parameter assignments) from the "volatile data" area on the CF card.
Proceed as follows:
1. Establish the connection between the SIMOTION D and the PG/PC.
2. In SIMOTION SCOUT, the CF card is written to by means of the "Copy RAM to ROM"
menu command.
Writing to a CF card without a SIMOTION D module
With a suitable memory card adapter, you can write to the CF card directly via a PG/PC.
Always save your project data to the CF card using the PG/PC before you upgrade the
SIMOTION firmware, for example.

Note
Files that have been written to the CF card with "Copy RAM to ROM" in SIMOTION SCOUT
must not be modified or deleted with Windows. This can corrupt the project.

Service and maintenance
8.5 SIMOTION Compact Flash card
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 297
8.5.3 Formatting the CompactFlash card
You can format the CF card, for example, if it is corrupt. Proceed as follows:
1. Insert the CompactFlash Card into a CompactFlash Card adapter connected to your
PG/PC.
2. Format the CF card in Windows (FAT or FAT16 file system).
3. If the boot sector of the CF card is also defective, you will have to rewrite the bootloader.
NOTICE

The CF card must only be formatted with FAT or FAT16, and must not be formatted with
FAT32 or NTFS.
See also
Bootloader on the CompactFlash card (Page 297)
8.5.4 Bootloader on the CompactFlash card
Writing a boot loader
A boot loader may need to be written in the following situations:
When a new boot loader is required for the SIMOTION D firmware version used
When a new boot loader is required for the SIMOTION D hardware version used
When the boot loader is defective.
The boot loader version can be read out using the SIMOTION SCOUT device diagnostics. If
this is not possible, the boot loader version may be incorrect. Possible description of error:
All eight LEDs light up yellow.
In this case, replace the boot loader version with the current version.
Use the "Options > Write boot sector..." function to write the boot loader version in the
SIMOTION SCOUT to the CF card.

Note
Up to and including V4.2:
You require PG/PC administrator rights to write to the boot sector. If you do not have
administrator rights on your PG/PC, an administrator can enter an administrator login for you
to use this function under "Options" > "Settings" > "Rights".

Service and maintenance
8.5 SIMOTION Compact Flash card
SIMOTION D4x5
298 Commissioning and Hardware Installation Manual, 11/2010
Detailed information on the compatibility relationships for the CF card, boot loader version,
SIMOTION D hardware and SIMOTION firmware version can be found in the software
compatibility list. This list is available both in the documentation supplied on the SIMOTION
SCOUT DVD (\1_Important\English\Compatibility\...) and on the Internet at
(http://support.automation.siemens.com/WW/view/en/18857317).
8.5.5 Recommended method for dealing with CF cards
Handling CF cards correctly
Please note the following when handling the CF card:
The CF card may only be inserted or removed when the system is de-energized.
CF cards are not designed to be rewritten as many times as the user wishes.
With this in mind, you should avoid writing user data from the application to the CF card
cyclically. Depending on the system, a write operation from the application may trigger
one or more write operations on the CF card. Therefore, we recommend you adopt a
conservative approach in terms of the number of writing processes. In other words, do
not perform more than 100,000 write access instances from the user program over the
estimated service life of the application.
Switching off the SIMOTION D Control Unit during write accesses to the CF card must be
avoided at all costs (examples of write accesses to the CF card: "Copy RAM to ROM",
savePersistentMemoryData, _saveUnitDataSet, _exportUnitDataSet, etc.). In the worst
case scenario, switching off the SIMOTION D Control Unit during write access can
damage the file system on the CF card. In this case, the CF card must be reformatted
and the firmware/user data reloaded. During this process the licenses remain on the
CF card.
8.5.6 Card reader for CF cards
Because of the quickly changing market and the large differences in the quality of card
readers, no specific recommendation can be made (except for the following card reader).
If problems occur identifying the CF card, this may be due to an incorrect power up of the
card reader.
Designation and ordering data
Card reader for CF/SD memory media,
with USB connection
Order number: 6FC5 335-0AA00-0AA0

SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 299
Diagnostics 9
9.1 Diagnostics via LED displays
Arrangement of LED displays
The front panel of the SIMOTION D4x5 has eight LED displays arranged in two rows of four.
There is also a 7-segment display below the blanking cover.
7-segment display
LED displays

Figure 9-1 7-segment and LED displays on the D4x5
Diagnostics
9.1 Diagnostics via LED displays
SIMOTION D4x5
300 Commissioning and Hardware Installation Manual, 11/2010
LED status key
The LED displays indicate the different operating modes and any errors occurring on the
SIMOTION D4x5. They do so by illuminating, flashing, or flickering in different colors.
The following table provides an overview of all occurring LED display combinations.
Meaning of the characters/symbols used:
1 = LED on
0 = LED off
0.5/1 = flashing LED (0.5 Hz)
2/1 = flashing LED (2 Hz)
= flickering LED
x = LED can light up
9.1.1 SIMOTION D4x5 and SINAMICS Integrated displays
Diagnostics
9.1 Diagnostics via LED displays
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 301
LED displays
Every LED can illuminate in yellow, red, or green. In the following table, the color of the LED
is indicated along with the illumination status.
Table 9- 1 LED displays
Meaning LED display
RDY RUN STOP SU/PF SF DP1 DP2 OPT
Power-up 1
(yellow)
1
(yellow)
1
(yellow)
1
(yellow)
1
(yellow)
1
(yellow)
1
(yellow)
1
(yellow)
Power-up of the D4x5 without CF card
or with CF card without valid operating
system (the boot loader may be
defective).
1
(yellow)
1
(yellow)
1
(yellow)
1
(yellow)
1
(yellow)
1
(yellow)
1
(yellow)
1
(yellow)
Incorrect firmware
(e.g. D4x5-2)
x 2/1
(yellow)
2/1
(yellow)
2/1
(yellow)
2/1
(yellow)
2/1
(yellow)
2/1
(yellow)
x
CF card has begun to boot, however, an
error has occurred (faulty FW).
0.5/1
(red)
0 0 0 0 0 0 0
BIOS update (red) x x x x x x x
D4x5 is ready to operate: SIMOTION
task system is running, and SINAMICS
Integrated is ready to operate
1
(green)
x x x x x x x
Read or write access to CF card
(yellow)
x x x x x x x
RUN X 1
(green)
0 0 x x x x
Transition from RUN - STOPU X 1
(green)
0 2/1
(yellow)
x x x x
Transition from STOPU - RUN x 2/1
(green)
0 1
(yellow)
x x x x
STOPU x 0 0 1
(yellow)
x x x x
Service mode (axis control panel /
measuring function)
x 2/1
(green)
0 2/1
(yellow)
x x x x
Transition from STOPU - STOP x 0 2/1
(yellow)
1
(yellow)
x x x x
STOP x 0 1
(yellow)
0 x x x x
Transition from STOP - STOPU x 0 1
(yellow)
2/1
(yellow)
x x x x
Request for memory reset by the D4x5
itself or via the mode selector
x 0 0.5/1
(yellow)
0 x x x x
Overall reset in progress active
1)
x 0 0 0 0 0 0 0
Memory reset completed x 0 1
(yellow)
0 0 0 0 0
An interrupt that can be acknowledged
(alarm, message, note) is pending
x x x X 1
(red)
x x x
Diagnostics
9.1 Diagnostics via LED displays
SIMOTION D4x5
302 Commissioning and Hardware Installation Manual, 11/2010
Meaning LED display
RDY RUN STOP SU/PF SF DP1 DP2 OPT
"FAULT" state
(7-segment display
shows "F").
For details, see "7-segment display" and
"Special operating modes"

(red)

(red)

(red)

(red)

(red)

(red)

(red)

(red)
HOLD mode
SIMOTION switches to HOLD mode as
soon as the program comes to a
breakpoint. When the program leaves
the breakpoint, SIMOTION switches out
of HOLD mode
x 0.5/1
(green)
1
(yellow)
1
(yellow)
x x x x
"RESET" state
(7-segment display
shows "8")
For details, see "7-segment display" and
"Special operating modes"
2/1
(red/yell
ow)
x x x x x x x
Incompatible hardware; SIMOTION
Kernel is no longer operating with
complete functionality on the hardware
being used
1
(yellow)
1
(red)
x x x x x x
Underlicensing of technology/
option objects
x x x x 0.5/1
(red)
x x x
SINAMICS Integrated
Firmware initialization 1
(yellow)
x x x x x x 0
Module identification (identification via
LED) selected via SCOUT or with
p124[0]=1.
1
(yellow)
x x x x x x x
Commissioning/reset 0.5/1
(green)
x x x x x x 0
SINAMICS Integrated is ready for
operation and cyclic DRIVE-CLiQ
communication is taking place.
1
(green)
x x x x x x x
General SINAMICS Integrated error
(check parameterization/configuration)
2/1
(red)
x x x x x x x
SINAMICS Integrated has not powered
up (SINAMICS firmware not available or
faulty), or a fault has occurred
1
(red)
x x x x 0 0 x
Read or write access to CF card
(yellow)
x x x x x x x
Upgrade/downgrade of DRIVE-CLiQ
components running
0.5/1
(yellow)
x x x x x x x
The upgrade/downgrade of DRIVE-CLiQ
components is completed (power
OFF/ON of the upgraded/downgraded
devices is necessary)
2/1
(yellow)
x x x x x x x
PROFIBUS DP interfaces as master
No parameter assignment available x x x x x 0 0 x
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Meaning LED display
RDY RUN STOP SU/PF SF DP1 DP2 OPT
At least one slave is missing. x x x x x 1
(red)
1
(red)
x
Bus status "Clear" x x x x x 0.5/1
(green)
0.5/1
(green)
x
Bus status "Operate" x x x x x 1
(green)
1
(green)
x
PROFIBUS DP interfaces as i-slave
No parameter assignment available x x x x x 0 0 x
No parameter assignment master
available
x x x x x 1
(red)
1
(red)
x
Bus status "Clear" x x x x x 0.5/1
(green)
0.5/1
(green)
x
Bus status "Operate" x x x x x 1
(green)
1
(green)
x
PROFINET IO interface (CBE30, X1400)
No CBE30 connected x x x x x x x 0
CBE30 runs error-free x x x x x x x 1
(green)
Bus error (CBE30):
Failure of a connected I/O device.
At least one of the assigned I/O
devices cannot be addressed.
Incorrect or no configuration.
x x x x x x x 2/1
(red)
Firmware downloaded x x x x x x x 2/1
(green)
Firmware download faulty x x x x x x x 0.5/1
(red)
Upgrading SIMOTION devices (device update tool)
Upgrade/downgrade running x x x x 0.5/1
(green)
x x x
Upgrade/downgrade completed with
error
x x x x
(red)
x x x
Upgrade/downgrade completed without
error
3)

x x x x 0
4)
x x x
Upgrade data is being copied from USB
stick to CF card
0.5/1
(yellow/
green)
x x x x x x x
Booting is not possible from the used
USB stick
0.5/1
(yellow)
min.
10 s
x x x x x x x
Upgrade data copying from USB stick to
CF card completed with error

(red)
x x x x x x x
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Meaning LED display
RDY RUN STOP SU/PF SF DP1 DP2 OPT
Upgrade data copying from USB stick to
CF card completed without error
1
(green),
min.
10 s
2)

x x x x x x x
Backing up diagnostics data and non-volatile data
Backing up diagnostic data and non-
volatile data (backup running)
x x
(yellow)

(yellow)
x x x x
Backing up diagnostic data and non-
volatile data (backup completed)
x
(green)
x x x x x x
The RDY LED of the SIMOTION D4x5 does not flash yellow/green as in the case of CUs, but instead lights up yellow
constantly.
1)
The LED state appears only very briefly due to the speed at which the "overall reset" is completed. The modules then
power up (the STOP LED flashes yellow at 2 Hz).
2)
The copying procedure is completed when the SF LED is steady green for at least 10 s
3)
The upgrade or downgrade has been completed when the SF LED goes out. The device then boots up automatically in
the upgraded or downgraded configuration (SF LED display then depends on the operating mode of the device).
Additional references
More detailed information can be found in the Upgrading SIMOTION Devices Operating
Instructions.
7-segment display
The 7-segment display provides further status information in addition to the LED displays.
Table 9- 2 States of the 7-segment display
State Meaning
8 Module in the RESET state
(RESET button pressed; overtemperature; faulty/disconnected
fan/battery module)
F F state (FAULT)
In the F state, the CPU of the D4x5 is in HOLD mode, i.e. no
software is running
(D4x5 operating system is stopped)
6 SIMOTION D has powered up
Flashing point Communication is taking place between SIMOTION and
SINAMICS Integrated
Diagnostics
9.1 Diagnostics via LED displays
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Special operating modes
The following "special operating modes" are displayed via the status LEDs and the
7-segment display.
F state (FAULT)
In the F state, the CPU of the D4x5 is in HOLD mode, i.e. no software is running (D4x5
operating system is stopped).
The state occurs for faults to which the D4x5 operating system cannot react (e.g. when the
max. module temperature has been excessively exceeded).
The state is displayed as follows:
All LEDs flicker red and
The 7-segment display shows "F"
Possible measures:
Check the CF card
Perform a commissioning again
Correct any overtemperature
Replace the D4x5
The state can only be exited by switching the D4x5 off and on.
RESET state (permanent RESET)
In the RESET state, the CPU of the D4x5 is in a permanent RESET, i.e.
No software is running (D4x5 operating system is stopped) and
The hardware is in a state that produces less power loss
The state is displayed as follows:
The RDY LED flashes red/yellow at 2 Hz
The 7-segment display shows "8"
Possible measures:
Correct any overtemperature
Ensure that the 24 V supply is stable without any power dips
Connect a fan/battery module (only on modules that require this)
The state can only be exited by switching the D4x5 off and on.
Diagnostics
9.1 Diagnostics via LED displays
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9.1.2 LED displays of the PROFINET interface
Position of the PN interface of the CBE30
Fault (red) LED
Port 1
Port 2
Port 3
Port 4
X1400 interface
Activity LED (yellow) for
each port
Link LED (green) for each port
Sync (green) LED

Figure 9-2 CBE30 front view
LED displays
Table 9- 3 Meaning of the LED displays
Name Color State Meaning
LINK Green On A different device is connected to port x and a physical connection
exists.
ACT Yellow Flashing Data is being received or sent at port x.
Off PROFINET interface is operating without error; the data exchange to
all configured I/O devices is running.
On PROFINET interface bus fault
No physical connection to a subnet/switch.
Incorrect transmission rate
Full duplex transmission is not activated
Fault red
Flashing
(2 Hz)
Failure of a connected I/O device
At least one of the assigned I/O devices cannot be addressed.
Incorrect or no configuration.
Diagnostics
9.1 Diagnostics via LED displays
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Name Color State Meaning
Off The PROFINET interface has not synchronized yet to the send cycle
clock of PROFINET IO with IRT, or PROFINET IO with IRT has not
been configured (e.g. only PROFINET IO with RT or TCP/IP
communication).
If IRT has been configured for SIMOTION, the PROFINET interface
generates a local substitute cycle clock as long as there is no
synchronization to the send cycle clock of PROFINET IO with IRT:
SIMOTION task system has synchronized to the local substitute
cycle clock of the PROFINET interface. SINAMICS Integrated and
external isochronous DP interfaces are synchronized to the local
substitute cycle clock of the PROFINET interface.
On The PROFINET interface has synchronized to the send cycle clock of
PROFINET IO with IRT
If IRT data has been configured for SIMOTION, then the following
applies:
The task system of SIMOTION has synchronized to the send cycle
clock of PROFINET IO with IRT.
SINAMICS Integrated and external isochronous DP interfaces are
synchronized to the send cycle clock of PROFINET IO with IRT.
SYNC
1)
Green
Flashing
(2 Hz)
The PROFINET interface has synchronized to the send cycle clock of
PROFINET IO with IRT
If IRT data has been configured for SIMOTION, then the following
applies:
The task system of SIMOTION has synchronized to the send cycle
clock of PROFINET IO with IRT.
SINAMICS Integrated and external isochronous DP interfaces are not
yet synchronized to the send cycle clock of PROFINET IO with IRT.
1)
If no IRT has been configured, then generally no synchronization will be made to the send cycle
clock. LED is off.
9.1.3 LED displays of the Ethernet interface
The Ethernet ports are equipped with LEDs to display Link and Activity.
Table 9- 4 State of the Link and Activity LEDs
LED State Meaning
OFF No or faulty connection LINK (upper LED)
Lights up green Transfer rate 10 or 100 Mbit/s:
A different device is connected to port x and a
physical connection exists.
OFF No LAN connection ACT (lower LED)
Flickers yellow LAN connection
Data is being received or sent at port x

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9.1 Diagnostics via LED displays
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9.1.4 LED displays of the CX32 controller extension
The different states that occur during power-up are indicated by the LEDs on the CX32
controller extension.
The duration of the individual states varies.
If an error occurs, the power-up is terminated and the cause is indicated accordingly via
the LEDs.
At the end of an error-free power-up, all LEDs are switched off briefly.
After power-up, the LEDs are controlled via the loaded software.
9.1.4.1 Behavior of the LEDs during booting of the CX32
Table 9- 5 Load software 1
LED
RDY DP1
State Comment
Red Red Reset Hardware reset
Red, 2 Hz Red Error
D4x5 CompactFlash card not inserted
or
Load software 2 has not been installed on the
D4x5 CompactFlash card or is defective.

Table 9- 6 Load software 2
LED
RDY DP1
State Comment
Off Red Loaded
Off Yellow Running
Off Red, 2 Hz Error file Software on the D4x5 CompactFlash card is
incomplete or defective.
Off Red, 0.5 Hz Error CRC CRC faulty.
Off Off FW loaded

Table 9- 7 Firmware
LED
RDY DP1
State Comment
Off Off Initializing
Alternating Alternating Running See the table below
Diagnostics
9.1 Diagnostics via LED displays
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9.1.4.2 Behavior of the LEDs after booting of the CX32
Behavior of the LEDs after booting
Table 9- 8 Control unit - description of the LEDs after booting
LED Color State Description, cause Remedy
- OFF Electronics power supply is missing or outside
permissible tolerance range

Continuous
light
The component is ready and cyclic DRIVE-CLiQ
communication takes place or the CX32 waits for
initial commissioning
Green
2 Hz
flashing
light
Writing to the memory card
Continuous
light
At least one fault is present in this component Remedy and acknowledge
fault
Red
2 Hz
flashing
light
Boot error Check whether the D4x5
CompactFlash card is
inserted correctly
Replace the D4x5
CompactFlash card
Replace the CX32
Perform POWER ON
Green/
red
0.5 Hz
flashing
light
CX32 is ready for operation.
However, software licenses are missing
Obtain licenses
Continuous
light
System booting and DRIVE-CLiQ communication is
being established

0.5 Hz
flashing
light
Firmware update of the connected DRIVE-CLiQ
components running
-
Yellow
2 Hz
flashing
light
Firmware update is complete for components. Wait
for POWER ON for the components in question
Turn POWER ON for the
components in question
RDY
(READY)
Green/
yellow or
red/
yellow
1 Hz
flashing
light
Detection of the components via LED is activated
(p0124[0]).
Note:
Both options depend on the LED status when
activated via p0124[0] = 1
-
- Red Cyclic communication is not (yet) running.
Note:
The PROFIdrive is ready for communication when
the CX32 is ready for operation (see RDY LED)
DP1
PROFIdrive
cyclic
operation
Green Continuous
light
Cyclic communication is taking place.
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LED Color State Description, cause Remedy
0.5 Hz
flashing
light
Full cyclic communication has not yet taken place.
Possible causes:
D4x5 does not transfer any setpoints
During isochronous operation, no global control
(GC) or a faulty global control (GC) is
transferred by the D4x5

Red Continuous
light
Cyclic communication has been interrupted. Remedy fault
Yellow 2 Hz
flashing
light
Firmware checksum error (CRC error) Check whether the memory
card is inserted correctly
Replace the memory card
Replace the CX32
Perform POWER ON
9.2 Diagnostic data and non-volatile data
9.2.1 Overview
As of V4.1 SP2, and without the need for the SCOUT engineering system, you can use
simple operations (e.g. setting switches) to:
Back up diagnostic data, including non-volatile data (retain data) to the CF card; for
information, see Section Backing up diagnostic data and non-volatile data (Page 310).
Back up HTML pages (including the most up-to-date content) to the CF card for
diagnostic purposes; for information, see Section Diagnostics via HTML pages
(Page 315)
Restore backed-up non-volatile data (retain data); for information, see Section
Deleting/restoring non-volatile data (Page 317)
9.2.2 Backing up diagnostic data and non-volatile data
9.2.2.1 Diagnostic data
Following a fault on a SIMOTION device, diagnostic data (e.g. diagnostic buffer content, up-
to-date content of websites, etc.) can provide important information on the cause of the fault.
For this purpose, such data can be backed up to the CompactFlash Card using a simple
operation (e.g. by setting a switch on the D4x5).
You then have the following options for the diagnostic data:
You can retrieve it from the CompactFlash Card using a card reader
You can download it using IT DIAG or FTP
Diagnostics
9.2 Diagnostic data and non-volatile data
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You can also use it for diagnostic purposes or provide it to technical support for evaluation
purposes.
Various options are available to you for backing up diagnostic data:
Backup during operation (in STOP/STOPU/RUN mode); for information, see the section
titled Procedure: "Backup during operation" (Page 311)
Using IT DIAG;
IT DIAG also offers the option of retrieving diagnostic data online
Using a service selector switch
Backup while the module is powering up; for information, see the section titled Procedure:
"Backup during power-up" (Page 312).
Using a service selector switch
Controlling diagnostic data creation using an INI file stored on the CompactFlash Card
9.2.2.2 Non-volatile data (retain data)
In addition to diagnostic data, non-volatile data (retain data) is saved on the
CompactFlash Card. You can use these in situations where the non-volatile data has not
been saved on the CompactFlash Card using the _savePersistentMemoryData system
function, and you wish to restore the non-volatile data after a CPU has been replaced.

Note
While the non-volatile data are stored as a "PMEMORY.XML" backup file in the
"...USER/SIMOTION" directory using the _savePersistentMemoryData system function,
backing up diagnostic data and non-volatile data involves storing data in the
"...\USER\SIMOTION\HMI\SYSLOG\DIAG directory.

9.2.2.3 Procedure for backing up during operation
Procedure
The advantage of backing up diagnostic data and non-volatile data during operation is that
enhanced diagnostic information is available via HTML pages and TO alarm information.
Data is backed up:
With IT DIAG by selecting "Diagnostics > Diagnostics Files"; for information, see Section
Backing up diagnostic data and non-volatile data with IT DIAG (Page 318)
Using the service selector switch (see the description below)
Diagnostics
9.2 Diagnostic data and non-volatile data
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Service selector switch
To back up diagnostic data and non-volatile data using a service selector switch, proceed as
follows:
1. Set the service selector switch to "Diagnostics" (position "D").
The positions of the mode switch are not relevant (i.e. the set operating mode remains
unchanged).
The diagnostic data and non-volatile data can be created in STOP, STOPU, and RUN
modes.
Mode switch Service selector
switch

Figure 9-3 Mode switch and service selector switch
2. The diagnostic data and non-volatile data is backed up to the CF card.
The backup process is indicated by the status LEDs as shown in the following table:
3. Once the backup is complete, switch the D4x5 off.
4. Remove the CF card and reset the service selector switch to its original setting.
Table 9- 9 LED displays during backup process
Status LED displays on the D4x5
Backup in progress STOP LED and SU/PF LED flicker yellow
Backup complete RUN LED flickers green
9.2.2.4 Procedure for backing up during startup
Procedure
Backing up diagnostic data and non-volatile data during startup provides you with diagnostic
information without HTML pages / TO alarm information.
Backing up during startup is particularly advisable for SIMOTION devices that are not run
capable or have crashed.
Diagnostic data and non-volatile data is backed up
Using a service selector switch or
Using an INI file saved on the CF card
The procedure for each is described below.
Diagnostics
9.2 Diagnostic data and non-volatile data
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Service selector switch
Data is backed up using a service selector switch as follows:
1. Set the service selector switch to "Diagnostics" (position D).
The positions of the mode selector switch are not relevant (i.e. the set operating mode
remains unchanged).
Mode switch Service selector
switch

Figure 9-4 Mode switch and service selector switch
2. Switch the D4x5 off and back on again.
3. Wait for the device to power up.
The diagnostics data and non-volatile data is backed up to the CF card during startup,
provided that this is still possible and is not prevented by HW defects, for example. Note
the LED displays as shown in the following table.
4. Once the backup is complete, switch the D4x5 off.
5. Remove the CF card and reset the service selector switch to its original setting.
Table 9- 10 LED displays during backup process
Status LED displays on the D4x5
Backup in progress STOP LED and SU/PF LED flicker yellow
Backup complete RUN LED flickers green
INI file in the main CF card directory
1. Use a text editor (such as Notepad) to create a file called simotion.ini
2. Add the following text: DIAG_FILES=1
You must use a text editor and may not use any formatting in the text.
3. Copy the simotion.ini file to the main CF card directory.
4. Insert the CF card into the module, which is switched off.
5. Switch the D4x5 on and allow the SIMOTION device to power up.
The diagnostic data and the non-volatile data will be backed up to the data carrier during
power-up if this is still possible and is not prevented by HW defects, for example. Note
the LED displays as shown in the following table.
6. Once the backup is complete, switch off the SIMOTION device.
7. Remove the CF card.
Diagnostics
9.2 Diagnostic data and non-volatile data
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Table 9- 11 LED displays during backup process
Status LED displays on the D4x5
Backup in progress STOP LED and SU/PF LED flicker yellow
Backup complete RUN LED flickers green


NOTICE
To suppress startup in diagnostics mode again, you must delete the simotion.ini file from
the CF card.

9.2.2.5 Storing data
Storing diagnostic data and non-volatile data
You can find diagnostic data and non-volatile data on the CompactFlash Card in
the \USER\SIMOTION\HMI\SYSLOG\DIAG directory.
Copy these data and transfer them to technical support on request. A standard card reader
can be used to transfer the diagnostic data the CompactFlash Card via standard IT DIAG
sites or FTP.
The following data are stored:
Table 9- 12 Diagnostic data on the CompactFlash Card
File Application
DIAGBUF.TXT Diagnostic buffer in a simple text format:
Numerical values; no specific plain text. A text editor is used for evaluation
purposes.
PMEMORY.XML Non-volatile data (retain data)
Operator input can be used to restore the non-volatile data saved after a
CPU has been replaced.
(For information, see the section titled Restoring non-volatile data
(Page 317)).
TOALARMS.TXT Text file containing the pending TO alarms. Only TO IDs, alarm numbers,
and associated HEX values.
Note:
The TO alarms are only created if diagnostic data have been created during
operation (STOP/STOPU/RUN).
Website If the diagnostic data is backed up, the URLs are requested from the text file
(DIAGURLS.TXT) and stored as websites together with their content.
(For information, see the section titled Diagnostics for websites (Page 315)).
Note: Note:The websites are only stored if diagnostic data are created
during operation (STOP/STOPU/RUN).
Other files All other files stored in the directory are only of relevance to technical
support.
Diagnostics
9.2 Diagnostic data and non-volatile data
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Note
Use websites if you wish to back up diagnostic data in plain-text format. Websites enable
user-friendly diagnostics. In addition to the standard IT DIAG diagnostics sites, you have the
option of creating your own websites (e.g. for the axis status or for machine diagnostics).
Customized diagnostics sites are particularly suitable for application problems, as you can
define the contents yourself.

9.2.3 Diagnostics via websites
In the "DIAGURLS.TXT" text file, found in the ...\USER\SIMOTION\HMI\SYSLOG\DIAG
directory, you can specify HTML files whose status is to be stored on the CF card when
diagnostic data is created during operation. (For example, "devinfo.mcs" must be entered for
the "devinfo.htm" HTML page.)
Since the pages in question are stored together with their most up-to-date contents, this
enables the latest status information regarding the SIMOTION device, as well as the
machine/system, from the point at which diagnostic data were created (e.g. when the service
selector switch was activated) to be archived.
In addition to the standard IT DIAG diagnostics pages, it is possible to store customized
sites. Information on creating pages of this type can be found in, for example, Utilities &
Applications.
Diagnostics
9.2 Diagnostic data and non-volatile data
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Figure 9-5 Diagnostics buffer with generated diagnostic data
The following points must be noted for the DIAGURLS.TXT file:
A DIAGURLS.TXT file containing the standard IT DIAG pages is automatically created if
you have not stored your own DIAGURLS.TXT file.
Standard IT DIAG pages are entered "without" a path specification (e.g. "devinfo.mcs" for
the standard IT DIAG site "devinfo.htm").
Customized IT DIAG pages (such as "user.htm") in the \USER\SIMOTION\HMI\FILES
directory on the CF card must contain the FILES/ path specification.
If you have created subfolders (e.g. "myfolder" in the FILES directory), these must also
appear in the path.
Only one file name may be used per line.
Empty lines are not permitted (an empty line will be interpreted as the end of the list).
Diagnostics
9.2 Diagnostic data and non-volatile data
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No distinction is made between upper-case and lower-case letters.
It does not matter whether you use "\" or "/" in the path name.
lT DlAG
lT DlAG Standard pages
User pages

Figure 9-6 Depiction of DIAGURLS.TXT editor
Additional references
For detailed information about IT DIAG device and diagnostic information, see the
SIMOTION IT Ethernet-Based HMI and Diagnostic Functions Diagnostics Manual.
9.2.4 Deleting/restoring non-volatile data
Requirement
The diagnostic data and non-volatile data has been backed up to the CF card; for
information, see Section Backing up diagnostic data and non-volatile data (Page 310).
Diagnostics
9.2 Diagnostic data and non-volatile data
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Procedure
To restore non-volatile data after a CPU has been replaced, proceed as follows:
1. Insert the CF card into the new D4x5 (which must be switched off).
2. Set the service selector switch to the "Delete/restore non-volatile data" setting (switch
position "1").
The positions of the mode selector are not relevant (i.e. the set operating mode remains
unchanged).
Mode switch Service selector
switch

Figure 9-7 Switch position 1 for deleting/restoring non-volatile data
3. Allow the D4x5 to power up; the non-volatile data is first deleted and then restored while
this is taking place.
If there is a file called "PMEMORY.XML" in the "USER/SIMOTION" directory on the
CompactFlash Card, this will be restored (rather than the "PMEMORY.XML" file saved
using diagnostics in directory \USER\SIMOTION\HMI\SYSLOG\DIAG).
The order of priority for restoration is as follows:
/USER/SIMOTION/PMEMORY.XML
/USER/SIMOTION/PMEMORY.BAK
/USER/SIMOTION/HMI/SYSLOG/DIAG/PMEMORY.XML


Note
When the "Delete/restore non-volatile data" switch position is selected, the non-
volatile data of the D4x5 is first deleted and then restored by means of the PMEMORY
backup file.
4. Once the D4x5 has powered up, switch it off.
5. Reset the service selector switch to its original setting.
6. Switch the D4x5 back on.
9.2.5 Backing up diagnostic data and non-volatile data using IT DIAG
SIMOTION devices feature pre-configured, standard IT DIAG pages. These pages can be
displayed via Ethernet using a commercially available browser. Additionally, you have the
option of creating your own HTML pages and incorporating service and diagnostic
information.
Diagnostics
9.2 Diagnostic data and non-volatile data
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You can also use IT DIAG to back up diagnostic data and non-volatile data. IT DIAG is
opened by entering the IP address of the SIMOTION device in the address bar of the
browser; e.g. http://169.254.11.22
This opens the IT DIAG start screen. To back up diagnostic data and non-volatile data, call
up the "Diagnostic files" page from the "Diagnostics" menu.

Figure 9-8 IT DIAG
Diagnostics
9.3 Additional service and diagnostics options
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Table 9- 13 Functions on the "Diagnostic files" HTML page
Button Function
Create general diagfiles This button saves diagnostic data and non-volatile data in the
...\USER\SIMOTION\HMI\SYSLOG\DIAG directory. HTML files
used for diagnostics purposes are not saved.
Create html diagfiles This button is used to save diagnostics HTML pages on the data
carrier. It should be noted that only those pages that are listed in
the DIAGURLS.TXT file in directory
...\USER\SIMOTION\HMI\SYSLOG\DIAG are backed up, see
Section Backing up diagnostic data and non-volatile data
(Page 310).
Zip all diagfiles The "zip all Diagfiles" button enables you to compress
diagnostics files. This stores all files and folders in a ZIP file in
directory ...\USER\SIMOTION\HMI\SYSLOG\DIAG, while
retaining the folder structure.
Get diagarchive This button is used to save the ZIP archive to connected
programming devices/PCs.
Delete all diagfiles This button is used to delete all data stored in the
...\USER\SIMOTION\HMI\SYSLOG\DIAG directory; the directory
itself is not removed, however.
You can find diagnostic data and non-volatile data on the CF card in the following directory:
\USER\SIMOTION\HMI\SYSLOG\DIAG
Additional references
Detailed information can be found in the SIMOTION IT Ethernet-Based HMI and Diagnostic
Functions Diagnostics Manual.
9.3 Additional service and diagnostics options
9.3.1 SIMOTION Task Profiler application
The SIMOTION Task Profiler is a dedicated application installed parallel to
SIMOTION SCOUT during SIMOTION SCOUT setup. The Task Profiler can be called in
online mode using device diagnostics in SIMOTION SCOUT or the Windows application. In
the event of a malfunction or error, the Task Trace data can be written to a directory or the
CompactFlash Card. They can then be processed using the Task Trace Viewer.
Additional references
For detailed information, refer to the SIMOTION Task Trace Function Manual.
Diagnostics
9.3 Additional service and diagnostics options
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9.3.2 Diagnostics using IT DIAG
The SIMOTION D features an integrated Web server.
In addition to customized Web pages and the option of performing firmware and project
updates, IT DIAG provides comprehensive device and diagnostic information that can be
called up using a standard PC with Internet Explorer.
As of firmware version V4.2, it is no longer necessary to purchase licenses for SIMOTION IT
DIAG and SIMOTION OPC-XML.
Additional references
Detailed information can be found in the
SIMOTION IT Ethernet-Based HMI and Diagnostic Functions Diagnostics Manual.
Diagnostics
9.3 Additional service and diagnostics options
SIMOTION D4x5
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SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 323
Configuration of drive-related I/Os (without symbolic
assignment) A

Further information and programming examples for configuring drive-related I/Os without
symbolic assignment can be found
On the Internet at http://support.automation.siemens.com/WW/view/en/29063656
(http://support.automation.siemens.com/WW/view/en/29063656)
In SIMOTION Utilities & Applications
SIMOTION Utilities & Applications is part of the scope of delivery of SIMOTION SCOUT.
The configuration of local measuring inputs is fundamentally different to the configuration of
global measuring inputs.
The assignment of the local measuring inputs is permanently related to the hardware of the
control unit and is performed
On the drive side via the drive expert list and
During the configuration of the TO measuringInput via the measuring input number
Local and global measuring inputs have different properties. Detailed information on the
differences can be found in the appendix,
in Section Local and global measuring inputs (Page 323)
Information on the configuration can be found
For global measuring inputs (with symbolic assignment) in Section Configuration of global
measuring inputs (Page 230)
For local measuring inputs in the appendix, in Section Configuration of local measuring
inputs (Page 325)
A.1 Local and global measuring inputs
Local and global measuring inputs
Depending on the used hardware platform, the following local and global measuring inputs
are available for the measuring tasks:
Local measuring inputs are axis-related and implemented in the SINAMICS drive. The
actual position value is measured.
Global measuring inputs can be freely assigned to the axes and add an internal time
stamp to the measurement result for more precise determination of the axis positions.
The term "central measuring input" is also used within the context of drives.
Configuration of drive-related I/Os (without symbolic assignment)
A.1 Local and global measuring inputs
SIMOTION D4x5
324 Commissioning and Hardware Installation Manual, 11/2010
Table A- 1 Comparison of local and global measuring inputs
Local measuring input Global measuring input
Hardware supported D410, D4x5, D4x5-2 (terminal
X122/X132), CX32, CX32-2, CU310,
CU320, CU320-2
TM15, TM17 High Feature, D410,
D4x5, D4x5-2 (terminal X122, X132,
X142), CX32, CX32-2, CU310, CU320,
CU320-2
Measurement operation With a signal edge at the relevant input,
the current actual values of an encoder
connected to a control unit are
measured with positioning accuracy to
determine lengths and distances.
With a signal edge at the relevant input,
the current actual values of one or
more encoders are measured using
time stamp functionality with positioning
accuracy in order to provide information
for determining lengths and distances
(possible with any encoders included in
the project).
Configuration of the TO measuringInput
in the SIMOTION SCOUT
The assignment of inputs is always
permanent depending on the hardware
of the control unit and is performed
during the configuration of the TO
measuringInput using the measuring
input number.
The assignment of inputs is not fixed
depending on the hardware and is
performed during the configuration of
the TO measuring input by means of
symbolic assignment or the hardware
address.
TO measuringInput setting: Single
measurement
(Measurement jobs must be issued
individually for each measurement.
Several interpolation cycle clocks lie
between two measurements.)
Yes Yes
TO measuringInput setting: Cyclic
measuring
(Measuring is activated just once and
runs cyclically until deactivated.)
No Yes
D410, D4x5, D4x5-2 (terminal X122,
X132), CX32, CX32-2, CU310, CU320,
CU320-2:
The minimum interval between two
measurements is three servo cycle
clocks (max. two edges per
measurement).
D4x5-2 (terminal X142), TM17 High
Feature:
The minimum interval between two
measurements is one servo cycle clock
(max. two edges per measurement).
TM15:
No cyclic measurement available
Use of multiple TO measuringInputs on
one axis/encoder, whereby these can
be active concurrently.
No Yes
Listening TO measuringInput No Yes
Measuring on virtual axes No Yes
Measuring on axes attached to a
different drive unit
No Yes
SIMOTION Utilities & Applications includes, for example, a tool to estimate:
Configuration of drive-related I/Os (without symbolic assignment)
A.2 Configuring local measuring inputs
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 325
The time between a measurement job being initiated and it being effective in the drive
The minimum time between two measurement jobs
SIMOTION Utilities & Applications is part of the scope of delivery of SIMOTION SCOUT.
Table A- 2 Measuring inputs - overview of quantity structures and functionality
Maximum available quantity structure
D410, CU310,
CX32
D4x5, CU320 CX32-2 D4x5-2
- X122/X132
- X142
TM15 TM17 High
Feature
Maximum number of
measuring input inputs
3 6 4 - 8
- 8
24 16
Can be configured as a
local measuring input
x x x - 8
- 0
- -
Can be configured as a
global measuring input
x x x - 8
- 8
x x
A.2 Configuring local measuring inputs
Configuring local measuring inputs
Local measuring inputs are always permanently assigned to an axis (drive). They are
configured separately for each drive. The drive and the measuring input input must always
be located on the same control unit. The measurement results are transferred using the axis
message frame in accordance with the PROFIdrive profile. Message frame 39x does not
need to be configured for local measuring inputs.
The settings for the use of the local measuring inputs must be made in the expert list.
In order to use an I/O terminal on a D4x5, CX32 or SINAMICS control unit as measuring
input input, proceed as follows:
1. Double-click the "Inputs/outputs" entry below the control unit in the project navigator.
2. Click the "Bidirectional digital inputs/outputs" tab.
3. In this tab, configure the required I/O terminal as input. The configuration can also be set
channel-granular on the p728 parameter using the expert list of the control unit.
Specification of the measuring input input terminal must be made in the expert list of the
respective drive for local measuring inputs.
Configuration of drive-related I/Os (without symbolic assignment)
A.2 Configuring local measuring inputs
SIMOTION D4x5
326 Commissioning and Hardware Installation Manual, 11/2010
Table A- 3 Local measuring inputs, required settings in the expert list
Parameterization as Parameters in the expert list of the drive
D4x5, CU320 CX32, CU310
p488[0]
(measuring input 1 input terminal, encoder 1)
p488[1]
(measuring input 1 input terminal, encoder 2)
p488[2]
(measuring input 1 input terminal, encoder 3)
p489[0]
(measuring input 2 input terminal, encoder 1)
p489[1]
(measuring input 2 input terminal, encoder 2)
Specification of the
input terminal of the
measuring input in the
expert list of the drive
p489[2]
(measuring input 2 input terminal, encoder 3)
DI/DO 9 or
DI/DO 10 or
DI/DO 11 or
DI/DO 13 or
DI/DO 14 or
DI/DO 15
DI/DO 9 or
DI/DO 10 or
DI/DO 11

As a maximum of three encoders can be assigned to a drive, the index [0...2] specifies
whether the measurement applies to encoder 1, 2, or 3.
The following must be taken into account:
Only two TO measuringInputs can be configured per TO axis or TO externalEncoder.
Only one TO measuringInput can be active on a TO axis or TO externalEncoder.
Table A- 4 Local measuring inputs, configuration of the TO measuringInput
Axis measuring system no. Under axis measuring system number, enter the number of the used
encoder system (namely, encoder 1, 2 or 3). Encoder system 1 is the
default setting.
Drive-related (local
measuring input)
Activate the checkbox when a local measuring input is used.
Measuring input number Enter here which measuring input is used (namely, 1 or 2). Input 1 is
the default setting.
Detailed information can be found in the SIMOTION Motion Control Output Cams and
Measuring Inputs Function Manual.

SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 327
Standards and approvals B
B.1 General rules
EN 61131, EN 60950
The SIMOTION programmable controller meets the requirements and criteria of the
standards EN 61131 and EN 60950.
CE marking


Our products satisfy the requirements and protection objectives of the EC
Directives and comply with the harmonized European standards (EN).
EMC Directive
SIMOTION products are designed for industrial use in accordance with product standard DIN
EN 61800-3, Category C2.
cULus Approval


Listed component mark for United States and the Canada Underwriters
Laboratories (UL) according to Standard UL 508, File E164110, File E115352,
File E85972.
EMC

USA
Federal
Communications
Commission
Radio Frequency
Interference
Statement
This equipment has been tested and found to comply with the limits for a
Class A digital device, pursuant to Part 15 of the FCC Rules. These limits are
designed to provide reasonable protection against harmful interference when
the equipment is operated in a commercial environment. This equipment
generates, uses, and can radiate radio frequency energy and, if not installed
and used in accordance with the instruction manual, may cause harmful
interference to radio communications. Operation of this equipment in a
residential area is likely to cause harmful interference in which case the user
will be required to correct the interference at his own expense.
Shielded Cables Shielded cables must be used with this equipment to maintain compliance with
FCC regulations.
Standards and approvals
B.1 General rules
SIMOTION D4x5
328 Commissioning and Hardware Installation Manual, 11/2010
USA
Modifications Changes or modifications not expressly approved by the manufacturer could
void the users authority to operate the equipment.
Conditions of
Operations
This device complies with Part 15 of the FCC Rules. Operation is subject to
the following two conditions: (1) this device may not cause harmful
interference, and (2) this device must accept any interference received,
including interference that may cause undesired operation.


CANADA
Canadian Notice This Class B digital apparatus complies with Canadian ICES-003.
Avis Canadien Cet appareil numrique de la classe B est conforme la norme NMB-003 du
Canada.


AUSTRALIA

D425, D435, D445, D445-1 meets the requirements of the AS/NZS CISPR 22.
Declaration of conformity
The current Declaration of conformity is available on the Internet at Declaration of conformity
(http://support.automation.siemens.com/WW/view/en/10805446/134200).
Electromagnetic compatibility
Standards for EMC are satisfied, if the EMC Installation Guideline is observed.

CAUTION
There is a risk of injury or of damage to assets. In hazardous areas, personal injury or
damage to assets can occur if plug-in connections are disconnected during operation.
Always de-energize your equipment in hazardous areas before disconnecting plug-in
connections.

Standards and approvals
B.2 Safety of electronic controllers
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 329


Note
The product standard EN 61800-3 describes the EMC requirements placed on "Variable-
speed drive systems". As such, it defines different limits depending on the location of the
drive system.
SINAMICS S120 power units are designed for use in the second environment. The term
second environment refers to all locations outside residential areas. These are basically
industrial areas which are supplied from the medium-voltage line supply via their own
transformers.
It is essential to follow the installation instructions in the SINAMICS S120 Manuals in order to
ensure compliance with emitted interference and immunity values.
For more information on this topic also refer to Catalog PM21 as well as the SINAMICS
Function Manuals.

B.2 Safety of electronic controllers
Introduction
The following remarks relate to fundamental criteria and apply irrespective of the type of
controller and the manufacturer.
Risk
A higher degree of safety standard applies to all applications and situations where there is a
risk of material damage or injury to persons if there is a failure. Special regulations specific to
the system apply to such applications. These must be taken into account for configuration of
the controller (e.g. VDE 0116 for furnaces).
For electronic controllers with safety responsibility, the measures required for preventing or
controlling faults depend on the hazard inherent in the plant. In this respect, the basic
measures listed above are no longer adequate once the hazard exceeds a certain potential.
Additional measures (e.g. double redundancy, tests, checksums, etc.) for the controller must
implemented and certified (DIN VDE 0801).
Standards and approvals
B.2 Safety of electronic controllers
SIMOTION D4x5
330 Commissioning and Hardware Installation Manual, 11/2010
The residual risk
When assessing his machine's risk in accordance with the EC Machinery Directive, the
machine manufacturer must take into account the following residual risks emanating from the
control and drive components:
1. Unintentional movements of driven machine components during commissioning,
operation, maintenance, and repairs caused by, for example:
Hardware defects and/or software errors in the sensors, controllers, actuators, and
connection technology
Response times of the controller and drive
Operating and/or ambient conditions not within the scope of the specification
Parameterization, programming, cabling, and installation errors
Use of radio devices / cellular phones in the immediate vicinity of the controller
External influences / damage
2. Exceptional temperatures as well as emissions of light, noise, particles, or gas caused by,
for example:
Component malfunctions
Software errors
Operating and/or ambient conditions not within the scope of the specification
External influences / damage
3. Hazardous shock voltages caused by, for example:
Component malfunctions
Influence of electrostatic charging
Induction of voltages in moving motors
Operating and/or ambient conditions not within the scope of the specification
Condensation / conductive contamination
External influences / damage
4. Electrical, magnetic and electromagnetic fields generated in operation that can pose a
risk to people with a pacemaker, implants or metal replacement joints, etc. if they are too
close
5. Release of environmental pollutants or emissions as a result of improper operation of the
system and/or failure to dispose of components safely and correctly

SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 331
ESD guidelines C
C.1 ESD definition
What does ESD mean?
All electronic modules are equipped with highly integrated modules or components. Because
of the technology used, these electronic components are very sensitive to overvoltages and
thus to discharge of static electricity.
The acronym ESD has become the established designation for such Electrostatic Sensitive
Devices. The ESD designation is used internationally to refer to electrostatic sensitive
devices.
Electrostatic sensitive devices are identified by the following symbol:

Figure C-1 Symbol for identification of electrostatic sensitive devices


CAUTION
Electrostatic sensitive devices can be irreparably damaged by voltages that are far lower
than anything a person can perceive. These voltages occur if you touch a component or the
electrical connection of a module without having previously discharged any static from your
body. Any damage that occurs to a module as a result of overvoltage is generally not
recognized immediately and only comes to light after the equipment has been operating for
some time.

ESD guidelines
C.2 Electrostatic charging of individuals
SIMOTION D4x5
332 Commissioning and Hardware Installation Manual, 11/2010
C.2 Electrostatic charging of individuals
Any person who is not conductively connected to the electrical potential of the environment
can accumulate an electrostatic charge.
This figure indicates the maximum electrostatic charges that can accumulate on an operator
when he comes into contact with the indicated materials. These values comply with the
specifications in IEC 801-2.
1
3
1
2
3
2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
5 10 20 30 40 50 60 70 80 90 100
Voltage in kV
(kV)
Relative air humidity in %
Synthetic material
Wool
Anti-static material, e.g. wood or concrete

Figure C-2 Electrostatic voltage that can accumulate on operating personnel
ESD guidelines
C.3 Basic measures for protection against discharge of static electricity
SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 333
C.3 Basic measures for protection against discharge of static electricity
Ensure sufficient grounding
When working with electrostatic sensitive devices, make sure that the you, your workstation,
and the packaging are properly grounded. This prevents the accumulation of static
electricity.
Avoid direct contact
You should only touch ESD components if unavoidable (for example, during maintenance
work). When you touch modules, make sure that you do not touch either the pins on the
modules or the printed conductors. If you follow these instructions, electrostatic discharge
cannot reach or damage sensitive components.
If you have to take measurements on a module, make sure that you first discharge any static
that may have accumulated in your body. To do this, touch a grounded metal object. Only
use grounded measuring instruments.
ESD guidelines
C.3 Basic measures for protection against discharge of static electricity
SIMOTION D4x5
334 Commissioning and Hardware Installation Manual, 11/2010

SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 335
Index

A
Active setting
Programming devices/PCs, 123
Ambient conditions
Climatic, 28
Automatic configuration, 168
Automatic controller setting
Position controller, 240
Speed controller, 239
Automatic position controller setting, 240
Automatic speed controller setting, 239
Axis
Creating with axis wizard, 204
Testing with the axis control panel, 212
Axis control panel, 211
Axis grouping, 15
DRIVE-CLiQ components, 16
SIMOTION D, 16
SINAMICS infeed, 16
SINAMICS power unit, 16
B
batteryexisting, 99
batterynecessary, 99
Boot loader, 297
Reading, 297
Writing, 297
Bus connector, 67
MPI, 72
setting the terminating resistor, 69
C
CE marking, 327
Commissioning
Download project to CF card, 163
Individual steps, 139
Load into file system, 163
Requirements, 135
Compact Flash card
Changing, 295
CompactFlash card
Content, 92
Formatting, 297
Writing to, 296
CompactFlash Card
inserting, 84
Properties, 83
Conditions of use, 26
Configuration
Global measuring inputs D4x5, 323
Local measuring inputs D4x5, 323
Measuring inputs on the D4x5, 323
Control Unit mounting
D445-1 next to Line Module, 35
On the side of the Line Module, 34
On the wall of the control cabinet, 35
With spacers, 36
Without spacers, 37
Controller optimization, 242
Automatic position controller setting, 240
Automatic speed controller setting, 239
Function generator, 242
Measuring functions, 242
Trace, 242
cULus Approval, 327
CX32
LEDs during booting, 308
CX32 configuration
Online configuration, 183
Overview, 174
Requirement, 176
topology, 179
Cycle clock scaling
external/internal PROFIBUS, 119
D
D4x5
Installing, 31
Removal and installation, 268
Replacing, 263
Upgrading, 263
Data
Deleting, 249
Data storage
Diagnostic data, 314
Data transmission rate
Aligning, 122
Declaration of conformity, 328
Index

SIMOTION D4x5
336 Commissioning and Hardware Installation Manual, 11/2010
Designs, 31
Diagnostic buffer entries, 96
Diagnostic data
Back up, 310, 318
Backing up during operation, 311
Backing up during startup, 312
Backing up via IT DIAG, 318
Data storage, 314
Diagnostics
7-segment display of the D4x5, 304
IT DIAG, 321
LED displays, 300
SIMOTION Task Profiler, 320
Via HTML, 315
Digital input/digital output
Connecting cables, 62
Wiring, 62
Distributed I/O systems, 18
DMC20/DME20
Creating, 236
Properties, 235
DP cycle, 118
PROFINET, 132
Drive optimization, 242
Drive wizard
Calling, 143
DRIVE-CLiQ
Advantages, 20
Components, 20
Connectable components, 56
Rules for wiring, 54
E
Electromagnetic compatibility, 328
EMC guidelines, 51, 327
EMERGENCY OFF concept, 51
EN 60950, 327
EN 61131, 327
Equipment
open, 31
Equipotential bonding, 49
ESD guideline, 331
Ethernet
Configuring addresses, 127
Interfaces, 126
Properties, 125
F
Fan/battery module, 100
D425/D435, 101
D445/D445-1, 101
Fan control, 100
Fan faults, 101
Max. permissible supply air temperature, 100
Firmware
Updating automatically, 293
Updating manually, 294
Upgrading, 285
Firmware downgrade, 294
Firmware update
IT DIAG, 286
Perform, 285
Front cover
Opening, 50
FW update
Perform, 285
G
Global measuring inputs D4x5, 323
Guideline
ESD, 331
H
Hardware
Configuring, 172
I
I/O systems
PROFIBUS, 18
PROFINET, 19
Released, 21
Installation
CBE30, 39
CX32, 40
D4x5, 31
TB30, 38
Integrated drive
Downloading a configuration, 172
SINAMICS S120, 142
Interface
X122/X132, 62
IT DIAG
Diagnostics, 321
FW update, 286
Index

SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 337
L
LED display
CBE30 PROFINET, 306
CX32, 309
D4x5 backup of non-volatile data, 304
PROFIBUS DP, 301
PROFINET interface, 301
SINAMICS Integrated with D4x5, 301
Upgrading the D4x5, 303
License
Back up, 291
Protection against deletion, 252
Undervoltage indicator, 301
Load
Into file system, 163
Project, 161
To the target system, 294
Local measuring inputs D4x5, 323
Local measuring inputs on the D4x5
Parameter, 325
M
Maintenance
Overview, 263
Measuring input
D4x5 overview, 230
Global for D4x5, 230
Measuring inputs on the D4x5
Local/global measuring inputs, 323
Mechanical rated conditions, 27
Memory model, 88
Memory reset, 249
via SIMOTION SCOUT, 250
with mode selector, 251
Module
Transport and storage conditions, 25
MPI bus
Bus connector, 72
Connection rules, 72
interface, 124
Parameters, 124
MPI interface, 117
N
Non-volatile data
Back up, 94, 318
Backing up, 311
Backing up via IT DIAG, 318
Diagnostics, 96
Power-up, 96
Reloading, 95
Restoring, 317
Saving to CompactFlash card, 91
O
Offline configuration
Overview, 141
Procedure, 142
Requirement, 141
Onboard I/Os of the D4x5
Configuration overview, 227
Overview, 226
Online configuration
Procedure, 166
Requirement, 166
Output cam
Configuration for D4x5, 233
Overview
Diagnostic data, 310
Upgrading and downgrading, 285
Overview of connections, 48
P
PG/PC connection
enabling the active setting, 123
via Ethernet, 112
via PROFIBUS, 110
Power failure, 95
Power supply
connecting, 53
Rules for the line voltage, 52
Safety regulations, 51
Switching on, 85
VDE guideline, 52
Power-up
Control unit, 85
PROFIBUS address, 117
PROFIBUS cable
Baud rate, 67
Cable length, 67
connecting, 68
Properties, 67
removing, 69
Rules for cabling, 68
PROFIBUS DP
Creating a new subnet,
Data transmission rate,
Definitions, 114
Index

SIMOTION D4x5
338 Commissioning and Hardware Installation Manual, 11/2010
DP cycle,
Interfaces,
PROFINET
Cable types, 75
Cabling, 73
Diagnostics via LED displays, 299
DP cycle, 132
IO controller, 133
IO device, 133
Properties, 133
Project
archiving on CF card, 165
creating, 107
Load, 294
Project update
IT DIAG, 286
Protection against external electrical phenomena, 53
R
References, 4
Reliability
Risk, 329
Replace module
DRIVE-CLiQ type, 269
Residual risk, 330
Restoring
Non-volatile data, 317
Restoring the default settings
SINAMICS Integrated, 253
Restoring the factory settings
SIMOTION D4x5, 253
Retain data
Back up, 273
Backing up, 311
Retain data and user data
Back up, 291
S
Safety information, 24
Safety of electronic controllers, 329
Service
Overview, 263
Service selector switch
Switch position 1, 318
Shield connection
Using, 63
SIMOTION D4x5
Hardware components, 15
Installation,
Possible applications, 14
Software components, 16
System overview, 13
User memory concept, 88
Variants, 14
SIMOTION SCOUT
Documentation, 23
engineering, 203
Installing, 107
SIMOTION Task Profiler, 320
SINAMICS Integrated
Restoring the factory settings, 253
Speed controller
Adjusting the P-Gain, 246
Optimum, 243
Starting the measuring function, 244
Standard IE cable types, 74
Starter, 23
Subnet
Connection components, 66
Connection rules, 70
Segment, 66
Terminating resistor, 66
Switching on
Requirement, 83
System
Powering down, 254
System components, 17
System cycle clock, 118
Bus cycle clock, 118
DP cycle, 132
IPO cycle clock, 118, 132
Ratios of system cycle clocks, 118
Servo cycle clock, 118
System function
_savePersistentMemoryData, 95
System variable
batteryexisting, 99
batterynecessary, 99
T
Task Profiler, 320
Terminating resistor, 66
Testing the drive, 200
TM41
Programming, 238
TM41 terminal module, 236
Configuring, 237
Totally Integrated Automation, 13
Index

SIMOTION D4x5
Commissioning and Hardware Installation Manual, 11/2010 339
U
UL certification, 327
Unit data
Back up, 273
User data
Deleting, 252
Load, 248
User memory concept, 88
Backup time, 90
Fan/battery module, 90
Non-volatile data, 89
Volatile data, 91
V
Variables
Back up, 273
Vibrations
Reduction, 27
Volatile data, 91

Index

SIMOTION D4x5
340 Commissioning and Hardware Installation Manual, 11/2010