SIMOTION SIMOTION D410. Preface. Description 1. Commissioning (hardware) 2. Configuring SIMOTION D410. Commissioning (software) 4

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1 Preface SIMOTION SIMOTION SCOUT SIMOTION SIMOTION Commissioning Manual Description 1 Commissioning (hardware) 2 Configuring SIMOTION 3 Commissioning (software) 4 Maintenance and service 5 Service and diagnostics 6 A Standards and approvals B ESD guidelines Valid for SIMOTION DP and PN 05/2009

2 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 device/system may only be set up and used in conjunction with this documentation. Commissioning and operation of a device/system may only be performed by qualified personnel. Within the context of the safety notes in this documentation qualified persons are defined as persons who are authorized to commission, ground and label devices, systems and circuits in accordance with established safety practices and standards. 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 NÜRNBERG GERMANY Copyright Siemens AG Technical data subject to change

3 Preface Contents of the commissioning manual This manual is part of the SIMOTION D4xx documentation package, Edition 05/2009. This manual describes commissioning of the SIMOTION devices DP and PN. Information blocks in this manual The following information blocks describe the purpose and use of the commissioning manual. Description This section provides information pertaining to the SIMOTION system and its integration into the information landscape. Commissioning (hardware) This section describes how to start up the device and what you must take into account. Configuring SIMOTION This section describes how to integrate SIMOTION in a project and how to configure the interfaces. Commissioning (software) This section describes how to configure a plant and how to test the drives and axes you configured. Maintenance and service This section describes how to replace a module, how to run updates, and how to modify settings. Service and diagnostics This section provides information about service and diagnostics options, as well as LED states. Appendices with factual information for reference (for example, Standards and Approvals, and ESD) Index for locating information. Commissioning Manual, 05/2009 3

4 Preface SIMOTION Documentation An overview of the SIMOTION documentation can be found in a separate list of references. This documentation is included as electronic documentation with the supplied SIMOTION SCOUT. The SIMOTION documentation consists of 9 documentation packages containing approximately 80 SIMOTION documents and documents on related systems (e.g. SINAMICS). The following documentation packages are available for SIMOTION V4.1 SP3: SIMOTION Engineering System SIMOTION System and Function Descriptions SIMOTION Diagnostics SIMOTION Programming SIMOTION Programming - References SIMOTION C SIMOTION P350 SIMOTION D4xx SIMOTION Supplementary Documentation Hotline and Internet addresses Technical support If you have any technical questions, please contact our hotline: Europe / Africa Phone (subject to charge) Fax Internet Americas Phone Fax mailto:techsupport.sea@siemens.com Asia / Pacific Phone Fax mailto:adsupport.asia@siemens.com 4 Commissioning Manual, 05/2009

5 Preface Note Country-specific telephone numbers for technical support are provided under the following Internet address: Calls are subject to charge, e.g /min. on the German landline network. Tariffs of other phone companies may differ. Questions about this documentation If you have any questions (suggestions, corrections) regarding this documentation, please fax or us at: Fax Siemens Internet address The latest information about SIMOTION products, product support, and FAQs can be found on the Internet at: General information: (German) (international) Product support: Additional support We also offer introductory courses to help you familiarize yourself with SIMOTION. Please contact your regional training center or our main training center at D Nuremberg, phone +49 (911) Information about training courses on offer can be found at: Commissioning Manual, 05/2009 5

6 Preface Disposal and recycling SIMOTION 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 Less material used because the unit is smaller and with fewer components thanks to integration in ASICs SIMOTION can be recycled because it is made with low-polluting materials. For state-of-the art environmentally friendly recycling and disposal of your old modules, contact your Siemens representative. To locate your representative, point your browser to: Internet address ( Further information / FAQs You can find additional information on this manual under FAQ at Internet address ( The following resources are also available: SIMOTION Utilities & Applications: The SIMOTION Utilities & Applications CD is included in the SIMOTION SCOUT scope of delivery and, along with FAQs, also contains free utilities (e.g. calculation tools, optimization tools, etc.) and application examples (readyto-apply solutions such as winders, cross cutters or handling). The latest FAQs for SIMOTION can be found at: Internet address ( SIMOTION SCOUT online help Additional documentation: Refer to the SIMOTION list of references (separate document). 6 Commissioning Manual, 05/2009

7 Table of contents Preface Description System overview System components SIMOTION DP display SIMOTION PN display The CompactFlash card Licensing Safety information Commissioning (hardware) Prerequisites for commissioning Inserting the Compact Flash card Switching on the power supply RESET button User memory concept SIMOTION memory model Properties of the user memories Operator actions and their impact on user memory Configuring SIMOTION Software requirements Inserting SIMOTION into a project Configuring the PROFIBUS DP interface (only DP) General information about PROFIBUS DP communication Assignment of the PROFIBUS addresses in HW Config Operating SIMOTION on PROFIBUS DP Creating a new PROFIBUS DP subnet Setting the DP cycle and system cycle clocks Rules for SIMOTION DP Operating the PROFIBUS interface (X21) as an MPI interface Configuring PROFINET (only for PN) General information about PROFINET communication Operating SIMOTION PN on PROFINET Setting the send cycles and system clocks Rules for SIMOTION PN Commissioning (software) Overview of commissioning Configuring the system in offline mode...59 Commissioning Manual, 05/2009 7

8 Table of contents Overview Accessing the drive wizard Configuring the components Aligning HW Config Downloading a project created offline to the target system Loading a project created offline to the CompactFlash Card Downloading a project, including sources and additional data Configuring the system in online mode Overview Establishing the online connection Starting automatic configuration Editing SINAMICS components Aligning HW Config Download the project to SIMOTION Additional information on configuring the SINAMICS Integrated Settings for DP slave properties Using vector drives Setting the time of day SINAMICS diagnostic buffer Acyclic communication with the drive Control properties and performance features Testing the configured drive using the drive control panel Creating an axis Testing the configured axis using the axis control panel Integrating additional encoders (optional) General information Configuring a second encoder on the SINAMICS drive Configuring a second encoder for a TO axis in SIMOTION Configuring external encoders in SIMOTION Configuring drive-related I/Os Onboard I/Os and terminal modules configuration overview Use of message frame 39x Free message frame configuring with P915/P916 (only TM15/TM17 High Feature) Configuring free message frames by means of BICO Expanding a message frame Using high-speed outputs for output cams on Using probe inputs on Outputs of cam outputs and probe inputs on TM15/TM17 High Feature Programming examples/additional information Creating and programming TM Overview Configuring TM41 at SINAMICS Integrated Creating a DMC DMC20 hub properties Creating a DRIVE-CLiQ hub Optimizing the drive and controller Overview of automatic controller setting Automatic speed controller setting Automatic position controller setting Measuring functions, trace, and function generator Commissioning Manual, 05/2009

9 Table of contents Manual speed controller optimization Downloading and saving user data Deleting data Overview of data deletion Resetting the memory of SIMOTION Deleting user data from the CompactFlash Card Restoring the default settings of SINAMICS Integrated Restoring the default settings of SIMOTION System shutdown Configuring Safety Integrated functions Maintenance and service Overview Replacing modules (spare part scenario) Removing and replacing the SIMOTION Replacing DRIVE-CLiQ components Replacing the fan Replacing the CompactFlash card Adapting a project (new device type/device version) Overview Replacing the SIMOTION device in HW Config Upgrading the device version of SINAMICS components Upgrading technology packages Upgrade the libraries Backing up variables Upgrading the CompactFlash Card's bootloader Downloading the project to the target system Performing a firmware and project update Overview Firmware update using a CompactFlash Card Firmware and project update using IT DIAG Firmware and project update using the device update tool SIMOTION CompactFlash Card Replacing the CompactFlash Card Writing to a CompactFlash card Formatting the CompactFlash Card Bootloader on the CompactFlash card Recommended method of handling CompactFlash Cards Service and diagnostics Diagnostics by means of LED displays Diagnostic data and non-volatile data Overview Backing up diagnostic data and non-volatile data Diagnostic data Non-volatile data (retain data) Procedure for backing up during operation Procedure for backing up during startup Storing data Diagnostics via websites Commissioning Manual, 05/2009 9

10 Table of contents Restoring non-volatile data Backing up diagnostic data and non-volatile data using IT DIAG Additional service and diagnostics options SIMOTION Task Profiler application Diagnostics using IT DIAG A Standards and approvals A.1 General rules A.2 Safety of electronic controllers A.3 Electromagnetic Compatibility B ESD guidelines B.1 ESD definition B.2 Electrostatic charging of individuals B.3 Basic measures for protection against discharge of static electricity Index Commissioning Manual, 05/2009

11 Description 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 is a module drive system for single axes, which solves demanding drive tasks for a very wide range of industrial applications. SIMOTION supplements D425, D435 and D445, the three power levels for multi-axis connections. SIMOTION D is an integral part of the Totally Integrated Automation (TIA) concept. TIA features standardized data management, configuration and communication over all products and systems. Thus, an extensive toolbox of automation modules is also available for SIMOTION. Application Combining a power module with SIMOTION forms a compact single drive for machine and plant engineering. Applications include: Machine concepts with central drive (e.g., pressing, printing and packaging machines,...) Modular machine concepts where the machine modules broken down to single axes Single drives with high accuracy, stability and concentricity requirements (compared with standard drives) in machine and industrial plant engineering Single drives for transport tasks (conveying, raising, lowering) Single drives with integrated PLC functionality and expanded motion control functionality such as output cam or cams Drives without power recovery (wire drawing, extruding) Drive connections with high availability requirements (incoming supply failure may not cause all axes to fail) Product variants SIMOTION comes in two variants: SIMOTION DP with PROFIBUS DP interface. SIMOTION PN with PROFINET interface. Commissioning Manual, 05/

12 Description 1.1 System overview System integration SIMOTION provides an optimized system platform for automation and drive solutions where the main focus is on motion control applications and technology tasks. The SIMOTION system is made up of three components: SIMOTION SCOUT Engineering System Runtime Software Hardware platforms The innovative SIMOTION concept involves integrating pure automation and motion functions, which have been traditionally isolated in the past. Figure 1-1 System solution SIMOTION can be used with all machines with motion control tasks. The focus is on a simple and flexible solution to a wide variety of motion control tasks. In order to achieve this in the best way possible, a new system approach has been introduced: the fusion of motion control with two other control functions, which are found in most machines: PLC and technology functions. This approach enables motion control of axes and machines with only one system. The same applies to technology functions, such as pressure control of a hydraulic axis. A seamless switch can be made from position-controlled positioning mode to pressure control. Combining the three control functions of motion control, PLC and technology functions has the following benefits: Lower engineering expenditure and higher machine performance. Interfaces between individual components requiring rapid response are no longer needed. Simple, standardized and transparent programming and diagnostics for the complete machine. 12 Commissioning Manual, 05/2009

13 Description 1.2 System components 1.2 System components Overview SIMOTION communicates with the components of the automation landscape via the following interfaces: PROFIBUS DP (SIMOTION DP only) PROFINET (SIMOTION PN only) DRIVE-CLiQ (DRIVE Component Link with IQ) Power Module Interface (PM-IF) SIMOTION D features a SINAMICS Integrated drive element. Communication with the SINAMICS Integrated (node 3) is via PROFIBUS mechanisms (DP integrated). The most important system components and their functions are listed in the following table. Table 1-1 System components Components SIMOTION System software Power supply (PS) Function... is the central motion control module. The module contains the programmable SIMOTION Runtime in SIMOTION and the SINAMICS S120 drive software. You can use the integrated rapid 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. The DRIVE-CLiQ interface permits a fast connection to the SINAMICS drive components. The system software is delivered separately on a CompactFlash Card (not included in the scope of delivery). Note: An additional license is not required for the real axis technology.... provides the electronic power supply for SIMOTION (e.g., SITOP power supply). Note: If the SIMOTION is snapped on to a PM340 Power Module, the Power Module may be used as the sole method of supplying power to the SIMOTION in certain cases (e.g. when digital outputs are not used, etc.). Also refer to the section titled in the SIMOTION Manual. Commissioning Manual, 05/

14 Description 1.2 System components PROFIBUS DP SIMOTION DP can communicate via PROFIBUS DP interface to the following components: Table 1-2 Components on PROFIBUS DP Components PG/PC programming device SIMATIC HMI device Drive units with PROFIBUS DP interface (e.g. CU310 DP) Other controls (e.g., SIMOTION or SIMATIC) Distributed I/O systems SIMATIC ET 200M SIMATIC ET 200S SIMATIC ET 200pro SIMATIC ET 200eco Function... configures, sets parameters, programs and tests using the SIMOTION SCOUT Engineering System (ES).... is used for operator control and monitoring functions. It is not absolutely essential for running SIMOTION.... convert speed setpoints into signals for controlling the motor and supply the power required to operate the motors. Can also be operated as an isochronous, equidistant Slave on the PROFIBUS DP. Modular I/O system for control cabinet installation and high channel densities. 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. Modular I/O system with IP65/IP67 rating for machine-related applications with no control cabinet; with new features such as more compact designs, integrated PROFIsafe safety technology, PROFINET connection and live module replacement. I/O system with IP65/IP67 rating for machine-related applications with no control cabinet, with a flexible and fast connection system in ECOFAST or M12. 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 to connect two PROFIBUS DP networks Teleservice adapter Remote diagnosis Note Note that only one real axis can be used on a SIMOTION. 14 Commissioning Manual, 05/2009

15 Description 1.2 System components PROFINET SIMOTION PN can communicate via PROFINET interface to the following components: Table 1-3 Components on PROFINET Components The master computer (at company and production management level) PG/PC programming device SIMATIC HMI device Drive units with PROFINET interface (e.g., SINAMICS S120 with CBE20) Other controls (e.g. SIMOTION or SIMATIC) Distributed I/O systems SIMATIC ET 200M SIMATIC ET 200S SIMATIC ET 200pro Function... communicates with other devices via Ethernet.... communicates with the SIMOTION SCOUT Engineering Systems (ES), STEP 7 and HMI (Human Machine Interface).... is used for operator control and monitoring functions. It is not absolutely essential for running SIMOTION.... convert speed setpoints into signals for controlling the motor and supply the power required to operate the motors. Modular I/O system for control cabinet installation and high channel densities. 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. Modular I/O system with IP65/IP67 rating for machine-related applications with no control cabinet; with new features such as more compact designs, integrated PROFIsafe safety technology, PROFINET connection and live module replacement. Other PROFINET I/O Gateways IE/AS Interface Link PN IO for the PROFINET IO gateway to AS Interface PN/PN coupler to connect two PROFINET IO networks Note Note that only one real axis can be used on a SIMOTION. Commissioning Manual, 05/

16 Description 1.2 System components I/O integration Note Please note that not all modules for the I/O systems listed are enabled 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. You can find an up-to-date list of the I/O modules that can be used with SIMOTION at: Internet address ( 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 devices with RT and IRT realtime classes may be connected to SIMOTION. These modules are integrated using the GSD file (PROFIBUS) or GSDML file (PROFINET) provided by the relevant device manufacturer. Note Please note that in isolated cases, additional boundary conditions must be fulfilled in order to integrate a module into SIMOTION. For example, "driver modules" in the form of function blocks are required for some modules, which enable integration or make it especially easy. For modules enabled for SIMOTION (e.g., S7-300 module FM 350-1, etc.), these driver modules are part of the SIMOTION SCOUT Engineering System command library. 16 Commissioning Manual, 05/2009

17 Description 1.2 System components DRIVE-CLiQ DRIVE-CLiQ offers the following advantages within the DRIVE-CLiQ topology rules: Independent expansion of components possible Automatic detection of components by the Control Unit Standardized interfaces in all components Uniform diagnostics, right down to component level Complete serviceability, right down to component level Mechanical parts are easy to use SIMOTION can communicate via DRIVE-CLiQ interface to the following components: Table 1-4 Components on DRIVE-CLiQ Components SINAMICS S120 AC DRIVE drive units (with CUA31/CUA32) TM15 and TM17 High Feature terminal modules TM31 terminal module TM41 terminal module TM54F terminal module SMx sensor modules Motors with DRIVE-CLiQ interface DMC20 Function... convert speed setpoints into signals for controlling the motor and supply the power required to operate the motors. The AC DRIVE component PM340 is connected via CUA31/CUA32. No more than one PM340 can be connected. Chassis power module is connected via DRIVE-CLiQ. Note: Components in booksize format are not supported! The terminal modules TM15 and TM17 High Feature are used to implement probe inputs and cam outputs. In addition, these Terminal Modules provide drive-related digital inputs and outputs with short signal delay times.... enables terminal expansion via DRIVE-CLiQ (additional analog and digital inputs/outputs).... enables terminal expansion (analog and digital inputs/outputs) and encoder simulation via DRIVE-CLiQ. The TM41 can be connected to a real axis. It is important to note that exactly one real axis can be configured on the.... enables terminal expansion (secure digital inputs/digital outputs) for SIMOTION Version V4.1 SP2 and higher, for controlling the secure motion monitoring functions of the integrated drive.... enable the acquisition of encoder data from the connected motors via DRIVE-CLiQ.... allow simplified commissioning and diagnostics, as the motor and encoder type are identified automatically.... expands the number of DRIVE-CLiQ nodes Note Please note that SIMOTION components in booksize format (CX32 Controller Extension, Motor Modules, Line Modules, etc.) are not supported. Commissioning Manual, 05/

18 Description 1.3 SIMOTION DP display 1.3 SIMOTION DP display View The following figure shows SIMOTION DP with the interfaces and front elements. Figure 1-2 Location of interfaces and front elements in SIMOTION DP Note The label underneath the mode selector lists the switch settings for the operating states of the SIMOTION. 18 Commissioning Manual, 05/2009

19 Description 1.3 SIMOTION DP display Interfaces The SIMOTION DP interfaces are described in the following tables. Table 1-5 SIMOTION interfaces Interface Digital inputs/outputs X121 DRIVE-CLiQ interface X100 PROFIBUS DP interface X21 Power Module Interface (PM-IF) Encoder interface (HTL/TTL/SSI) X23 EP terminals/temperature sensor connection X120 Power supply connection X124 Measuring sockets T0, T1, T2 and M Description 12-pin Mini Combicon: 4 digital inputs: for connecting switches or proximity sensors 4 digital inputs/outputs: for connecting actuators and sensors 8-pin RJ45plus socket to connect DRIVE-CLiQ nodes 9-pin SUB-D socket to connect to PROFIBUS DP 8-pin direct connector to connect to a blocksize power module 15-pin SUB-D socket for connecting HTL, TTL and SSI encoders. 8-pin Mini Combicon for connecting Safety Integrated input terminals or for connecting temperature sensing via KTY or PTC 4-pin screw terminal connection to connect the 24 V DC load power supply Sockets to output analog signals Type plates The following figure shows you all the information included on the type plate located on the side of the unit. Module designation Order number Serial number HW version Figure 1-3 SIMOTION nameplate Commissioning Manual, 05/

20 Description 1.3 SIMOTION DP display The type plate below is located on the front of the SIMOTION DP. Figure 1-4 SIMOTION DP nameplate (example) Note The contents of the individual nameplate fields on the current module may differ from those described in this Manual (e.g., updated product status, space for approvals and identifications, etc.). 20 Commissioning Manual, 05/2009

21 Description 1.4 SIMOTION PN display 1.4 SIMOTION PN display View The following figure shows SIMOTION PN with the interfaces and front elements. Figure 1-5 Location of interfaces and front elements in SIMOTION PN Commissioning Manual, 05/

22 Description 1.4 SIMOTION PN display Interfaces The SIMOTION PN interfaces are described in the following tables. Table 1-6 SIMOTION interfaces Interface Digital inputs/outputs X121 DRIVE-CLiQ interface X100 PROFINET interface (ports X200 and X201) Power Module Interface (PM-IF) Encoder interface (HTL / TTL / SSI) X23 EP terminals/temperature sensor connection X120 Power supply connection X124 Measuring sockets T0, T1, T2 and M Description 12-pin Mini Combicon: 4 digital inputs: for connecting switches and proximity sensors 4 digital inputs/outputs: for connecting actuators and sensors 8-pin RJ45plus socket to connect DRIVE-CLiQ nodes 8-pin RJ45plus socket to connect to PROFINET 8-pin direct connector to connect to a blocksize power module 15-pin SUB-D socket for connecting HTL, TTL and SSI encoders. 8-pin Mini Combicon for connecting Safety Integrated input terminals or for connecting temperature sensing via KTY or PTC 4-pin screw terminal connection to connect the 24 V DC load power supply Sockets to output analog signals Type plates The figure below shows all the information included on the type plate located on the side of the unit. Module designation Order number Serial number HW version Figure 1-6 SIMOTION PN type plate 22 Commissioning Manual, 05/2009

23 Description 1.4 SIMOTION PN display The following nameplate includes the MAC address of the PROFINET interface (ports X200 and X201) and is located on the front side of the module. Figure 1-7 SIMOTION PN nameplate (example) Note The contents of the individual nameplate fields on the current module may differ from those described in this Manual (e.g., updated product status, space for approvals and identifications, etc.). Commissioning Manual, 05/

24 Description 1.5 The CompactFlash card 1.5 The CompactFlash card CompactFlash Card The following figure shows you all the information included on the nameplate of the CompactFlash Card (CF card). Figure 1-8 CompactFlash Card Pre-installed runtime licenses For versions V4.1 SP1 HF6 and higher, pre-installed licenses are printed on the type plate of the CF card as a Z option underneath the order number. Example with Z option for a combined SIMOTION IT license + 2 TControl licenses: 6AU1400-2PA00-0AA0-Z Z=J00+T02 A maximum of 7 different Z options are printed on the type plate of the CF card. When there are more than 7 different Z options, the text "Z = see delivery order" is printed on the CF card in place of the Z option. Available Z options / licenses for SIMOTION D CF cards The following Z options are available for SIMOTION : TControl temperature control: Txx TControl license and number (e.g. T03 = 3 TControl licenses) SIMOTION IT: D00 IT DIAG license X00 OPC XML-DA license J00 Combined license for SIMOTION IT, comprises SIMOTION IT Virtual Machine for Java applications, SIMOTION IT DIAG and SIMOTION IT OPC XML-DA Safety functions: Fxx - License for SINAMICS Safety Integrated Extended Functions (e.g., F01 = 1 license for safety functions) 24 Commissioning Manual, 05/2009

25 Description 1.6 Licensing 1.6 Licensing SIMOTION licensing SIMOTION is a modular drive system for single-axis applications. contains the motion control technology functions for precisely one real axis (speed control, positioning, synchronous operation, cam). This means that these technology functions do not require an additional license. It is not possible to increase the number of axes using licenses. Along with the one real axis, further virtual axes can be configured and loaded. Licenses are required for runtime functions such as SIMOTION IT DIAG. These can be preinstalled on a CompactFlash Card (CF card) or ordered separately. Additional references For more information about license management, see the SIMOTION SCOUT Configuration Manual. General information about licensing can be found in the Motion Control SIMOTION, SINAMICS S120 catalog and motors for production machines catalog, PM Safety information Observe the following safety information when working with SIMOTION and its components! CAUTION The CompactFlash Card may only be unplugged and plugged in when SIMOTION is switched off (zero current)! The SIMOTION is in a de-energized state when all the LEDs are OFF. CAUTION The 50 mm clearances above and below the components must be observed. The ventilation openings may not be covered by connecting cables. Commissioning Manual, 05/

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27 Commissioning (hardware) Prerequisites for commissioning Prerequisites Prerequisites for commissioning the SIMOTION : You have completed installation and the wiring of your system with SIMOTION. A programming device / PC is available. Connecting a programming device / PC to SIMOTION You can interconnect the programming device / PC: With the PROFIBUS interface of SIMOTION DP (X21 connector) using a connecting cable. Information pertaining to cable lengths for PROFIBUS DP is available in the SIMOTION Manual. With the PROFINET interface of SIMOTION PN (X200 or X201 connector) using a twisted pair cable. Information pertaining to PROFINET communication is available in chapter "Configuring PROFINET". System requirements System requirements for hardware commissioning: The programming device must be equipped with a PROFIBUS or Ethernet adapter. The programming device / PC must be interconnected with SIMOTION DP (connector X21) for online communication on PROFIBUS DP. The programming device / PC must be interconnected with SIMOTION PN (connector X200 and 201) for online communication on PROFINET. You need a CF adapter on the programming device / PC to write to the Compact Flash Card (for example, a SIMOTION firmware update). Commissioning Manual, 05/

28 Commissioning (hardware) 2.2 Inserting the Compact Flash card 2.2 Inserting the Compact Flash card Properties of the CF card The CF card is mandatory for operation of SIMOTION. The SIMOTION kernel and the drive control software (SINAMICS firmware) are installed on the CF card. The CompactFlash card must be inserted when you start up SIMOTION in order to load the SIMOTION kernel. Note The CompactFlash Card may only be inserted or removed when the system is in a deenergized state. The SIMOTION is in a de-energized state when all the LEDs are OFF. Procedure Insert the CompactFlash Card as follows: 1. The insertion direction of the CompactFlash Card is identified by an arrow on the card and a matching arrow on the slot. Align the arrows when inserting the CompactFlash Card. 2. Gently push the CompactFlash Card into the card slot of SIMOTION until it engages. The properly inserted card does not protrude from the SIMOTION housing. Figure 2-1 Inserting the CompactFlash Card 28 Commissioning Manual, 05/2009

29 Commissioning (hardware) 2.3 Switching on the power supply 2.3 Switching on the power supply Checking the system Check the system installation and wiring once again before you switch it on. Observe the safety-relevant items of the following checklist: Have you observed all ESD measures when handling the components? Are all connectors properly inserted and interlocked / screwed on? Are all components grounded and all shields terminated? Have you made allowances for sufficient load capacity of the central power supply? Switching on the external power supply Power is supplied to the SIMOTION using an external power supply unit; for example, using SITOP power supplies (in special circumstances, the SIMOTION can also be supplied using the PM340 Power Module: refer to the SIMOTION Manual). Switch on the power supply after having checked off all items of the checklist. CAUTION It is imperative to prevent the external 24 VDC power supply to SIMOTION from being interrupted for a duration longer than 3 ms. Operation of SIMOTION is stopped on expiration of these 3 ms and can only be recovered by cycling power Off > On. Additional information is available in chapter "User memory concept". Commissioning Manual, 05/

30 Commissioning (hardware) 2.4 RESET button Startup of SIMOTION The startup of SIMOTION is initiated after the power supply is activated: 1. The RDY LED is lit and the red RUN/STOP LED briefly lights up at the beginning of the startup sequence. These LEDs can be used to monitor the startup sequence. Any errors are displayed. 2. Startup of the SIMOTION kernel. 3. All DRIVE-CLiQ connections (with SINAMICS S120 Power Module PM340, for example) are identified automatically. 4. Startup of SIMOTION is completed as soon as its RDY LED is lit in green color and the RUN/STOP LED is lit in yellow or green color. The SIMOTION is ready for configuring after successful completion of the startup. Note The components' firmware is automatically updated, depending on the FW version on the SINAMICS components and on the CompactFlash Card. During an FW update, please take note of the messages and alarms in the SIMOTION SCOUT detail window. An FW update on the SIMOTION is signaled by the RDY LED flashing yellow, while on the DRIVE-CLiQ components (TM, SMC, etc.) it is signaled by the RDY LED flashing red/green. FW update running: RDY LED flashes slowly (0.5 Hz) FW update complete: RDY LED flashes quickly (2 Hz) Go offline once all the FW updates are complete, then switch the 24 V supply for the upgraded initialization components off/on. 2.4 RESET button Arrangement The RESET button is located behind the blanking plate on the SIMOTION. Performing a reset operation A reset causes the entire system to be reset and requires the system to be ramped-up again. It is similar to a "Power On Reset" except that the 24 V power supply does not have to be switched off. 30 Commissioning Manual, 05/2009

31 Commissioning (hardware) 2.5 User memory concept 2.5 User memory concept SIMOTION memory model The following figure provides an overview of the SIMOTION memory model. Figure 2-2 SIMOTION memory model As a result, the SIMOTION Kernel ( firmware) contains the functions required for virtually all applications, and essentially acts as a PLC featuring an IEC compliant command set as well as 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 controllers. The next chapters provide information pertaining to user memories and to the sequences of specific user actions. See also Properties of the user memories (Page 32) Operator actions and their impact on user memory (Page 34) Commissioning Manual, 05/

32 Commissioning (hardware) 2.5 User memory concept Properties of the user memories Non-volatile data Non-volatile data is used with the objective of retaining user- and system-relevant data when SIMOTION is in de-energized state. You will find information about the area that can be used for non-volatile data in the SIMOTION SCOUT Configuration Manual. Non-volatile data available in SIMOTION devices: Table 2-1 Content of non-volatile data Non-volatile data Content Kernel data Last operating state 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 Retain TO DCC blocks Global device variables set with the "RETAIN" attribute Absolute encoder offset SAV blocks and user-defined blocks with retain behavior. Note DCC SIMOTION blocks with retain behavior act like retain variables in terms of copying RAM to ROM, performing a memory reset, downloading, backing up non-volatile data (_savepersistentmemorydata), and backing up data. With DCC SINAMICS blocks, data are only backed up using FRAM, i.e. not _savepersistentmemorydata. For additional details, please refer to the DCC Programming Programming Manual. The SIMOTION backed-up data have the following features: Table 2-2 Non-volatile data and real-time clock properties Properties Non-volatile data Real-time clock Location Non-volatile data resides in the FRAM of SIMOTION. The real-time clock is backed up using SuperCap. Backup battery No No Backup time Unlimited At least 5 days If the real-time clock backup time is exceeded, the time is reset. 32 Commissioning Manual, 05/2009

33 Commissioning (hardware) 2.5 User memory concept More information IP and DP parameters in non-volatile data The IP and DP parameters are loaded from configuration data on the CompactFlash Card during startup for use by the SIMOTION device. The SIMOTION can use the addresses defined in these data to go online. The IP and DP parameters on the CompactFlash Card are also written to non-volatile memory during startup. The IP and DP parameters in non-volatile data is retained and used by the SIMOTION device if the system is restarted with a CompactFlash Card which does not contain any configuration data. The SIMOTION device can always be made available online if the configuration was downloaded to the device at least once using SIMOTION SCOUT, or if the SIMOTION device was started up with Compact Flash Card. Volatile data (RAM/current RAM) Definition of the properties of volatile data: Volatile data resides in the RAM area of SIMOTION. The download data of SIMOTION SCOUT is written to this memory. These data is lost after the SIMOTION is shut down. Contents of the "volatile data" area: SIMOTION kernel Technology packages (TP) User data (programs, configuration data, parameters) Figure 2-3 Configuration data and system variables on volatile memory You can find additional information about memory management in SIMOTION in the SIMOTION Basic Functions Function Manual. Commissioning Manual, 05/

34 Commissioning (hardware) 2.5 User memory concept CompactFlash Card The CompactFlash Card contains the following data: SIMOTION kernel Technology packages (TP) User data (units, configuration data, parameters, task configuration) IP parameters (IP address, subnet mask, router address) DP parameters (PROFIBUS DP address, baud rate) Operator actions and their impact on user memory The operations marked with arrows in the figures titled "SIMOTION memory model" and "Configuration data and system variables in the volatile memory" and their effects on the user memory are described below. Download SIMOTION SCOUT The "Download" command transfers the following data from the Engineering System to the "volatile data" area: User data (units, configuration data, parameters, task configuration) Technology packages (TPs) The IP and DP parameters are furthermore saved to the "non-volatile data" area. The retain variables are initialized with their start values. This however, depends on the settings in SIMOTION SCOUT. Volatile data is lost if you shut down the SIMOTION module after the download. Copy RAM to ROM The "Copy RAM to ROM" command is used on the ES to save the following data to the CompactFlash Card: Technology packages and user data (units, configuration data, parameters, task configuration) of the "volatile data" area Actual values are copied to the "volatile data" area, depending on the settings in SIMOTION SCOUT. Note The "Copy RAM to ROM" command does not save the actual values of the retain variables to the CompactFlash Card: Use the "_savepersistentmemorydata" system function for this purpose. 34 Commissioning Manual, 05/2009

35 Commissioning (hardware) 2.5 User memory concept 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 take immediate effect are 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) are only written to the current RAM once the RESTART has taken place. 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 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 to PG" (for configuration data only) to re-establish a consistent system state. To save the configuration on the CompactFlash Card with protection against power failures, execute the menu command "Target system" > "Copy RAM to ROM". Note The "Copy current to RAM" command does not transfer the values of the system variables to the RAM memory. This means that it is not possible to execute "Save to memory card (Copy RAM to ROM)" or "Save in the engineering project (Load to PG)". 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 before being downloaded to the target device and saved. Startup of SIMOTION The SIMOTION kernel is loaded from the CompactFlash Card to the "volatile data" area during the startup of SIMOTION. Volatile data is lost if you shut down the SIMOTION module after the download. Data loaded from the CompactFlash Card at the next restart: The technology packages and user data to the "volatile data" area IP and DP parameters to the "non-volatile data" area Commissioning Manual, 05/

36 Commissioning (hardware) 2.5 User memory concept Backup of non-volatile data You have the following options for backing up non-volatile data on the CompactFlash Card: In the user program: With the "_savepersistentmemorydata" system function, the user program can back up the non-volatile data content to the CompactFlash Card. This backup prevents the retain variables and the absolute encoder position from being lost if a component is replaced. Using a switch setting (SIMOTION service selector switches) or IT DIAG For information on this, refer to the section titled Diagnostic data and non-volatile data (Page 172). The "_savepersistentmemorydata" function creates a backup copy of the non-volatile data. The backup copy is saved to the "PMEMORY.XML" backup file in the "USER/SIMOTION" folder. On system side it is always ensured that a consistent overall image of the non-volatile data is available at the next restart, even if there is a power failure during backup. An already existing backup file is renamed to "PMEMORY.BAK" before a new backup file is generated. If the backup to this new file fails (for example, due to insufficient storage capacity of the CompactFlash Card), the existing backup file is used in the next attempt to restore the content of non-volatile data. The backup file is deleted if the new file was successfully created. NOTICE Non-volatile data that are not backed up to the CompactFlash 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 have 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 were changed during operation and only stored in the runtime system. 36 Commissioning Manual, 05/2009

37 Commissioning (hardware) 2.5 User memory concept Startup and non-volatile data The table below describes the startup situations which may develop in terms of the nonvolatile data and how to handle such situations. Table 2-3 Startup situations with non-volatile data Situa Initial condition Result tion 1 Valid contents of non-volatile data. Startup of SIMOTION with the non-volatile data. The PROFIBUS address in non-volatile data is therefore valid, for example. 2 Invalid contents in non-volatile data, and neither a backup file (PMEMORY.XML), nor a backup copy (PMEMORY.BAK) exists. 3 Invalid contents in non-volatile data. A backup file (PMEMORY.XML) with valid contents is available. 4 Invalid contents in non-volatile data and in the backup file, and a backup copy (PMEMORY.BAK) is not available. 5 Invalid contents in non-volatile data and in the backup file, and a backup copy (PMEMORY.BAK) with valid contents is available. SIMOTION copies the factory defaults to its nonvolatile data and restarts using this data. The default PROFIBUS address is valid in this case, for example. SIMOTION copies the contents of the backup file to its non-volatile data and starts using this data. SIMOTION copies the factory defaults to its nonvolatile data and restarts using this data. The default PROFIBUS address is valid in this case, for example. SIMOTION copies the contents of the backup file to its non-volatile data and starts using this data. Diagnostics of non-volatile data Users can determine the status of non-volatile data by reading the diagnostic buffer and the system variables. The following message events are entered once in the diagnostics buffer when they occur: Table 2-4 Messages of the diagnostics buffer Entry Meaning To correct or avoid errors Non-volatile data loaded from file Non-volatile data successfully restored - (Persistent Data File Loading done) from the backup file to the CompactFlash Card. Non-volatile data loaded from the backup file (Persistent Data Backup File Loading done) Non-volatile data successfully restored from the backup copy to the CompactFlash Card. - Error while loading non-volatile data from a file (Persistent Data File Loading Failure) Backup file or backup copy could not be loaded. Possible causes: Backup file or backup copy not available Invalid data in backup file Use the "_savepersistentmemorydata" system function to generate a backup file with valid contents. Refer to the SIMOTION SCOUT Configuration Manual for information about how to read out the contents of the diagnostic buffer. Commissioning Manual, 05/

38 Commissioning (hardware) 2.5 User memory concept System variable "device.persistentdatapowermonitoring.persistentdatastate" indicates the status of non-volatile data after startup: Table 2-5 Status of non-volatile data after startup (persistentdatastate system variable) Status FROM_RAM (1) FROM_FILE (2) FROM_BACKUP (3) INVALID (4) Meaning Non-volatile data is activated in the SIMOTION device Non-volatile data was restored from the backup file Non-volatile data was restored from the backup copy Data in the non-volatile data and in the backup file/backup copy of backup file are invalid or non-existent/deleted. The SIMOTION device copied the factory settings to its non-volatile data and started up using this data. See also SIMOTION memory model (Page 31) 38 Commissioning Manual, 05/2009

39 Configuring SIMOTION Software requirements SIMOTION SCOUT Engineering System The SIMOTION SCOUT Engineering System must be installed on your programming device / PC in order to commission the SIMOTION. Please note the information on the latest "SIMOTION SCOUT" DVD. For information on how to install SIMOTION SCOUT on your programming device / PC, refer to the SIMOTION SCOUT Configuration Manual. 3.2 Inserting SIMOTION into a project Creating a project and configuring the programming device / PC interface Proceed as follows in order to create a project in SIMOTION SCOUT and to insert a SIMOTION : 1. Select the "Project > New..." menu. 2. Enter a name for your project in the "New Project" dialog box and confirm your entry with "OK". A new folder is generated in the Project Navigator and assigned the name of the project. 3. Double-click "Create new device" in the Project Navigator. The "Create New Device" dialog box opens. Select from the "CPU type" field and the characteristic of your module ( DP or PN) from the "Variant" field. Confirm with "OK". Note For SIMOTION V4.1 with PROFINET, you can choose from " PN-V2.1, SINAMICS...": IRT in accordance with PROFINET standard V2.1 " PN-V2.2, SINAMICS...": IRT in accordance with PROFINET standard V The "Properties" dialog box of the (PROFIBUS or PROFINET) interface opens where you set up the connection to the programming device / PC according to the module characteristics. Standardization of PROFINET in accordance with IEC has resulted in a transition from version V2.1 to V2.2. Please note that separate SIMOTION D firmware is available for PN V2.1 and PN V2.2. The required firmware can be found on the SCOUT DVD, as well as at: Internet address ( For PN V2.2, you require STEP7 Version V5.4 SP4 (at least). Mixed operation of PN V2.1 and PN V2.2 synchronization processes is not possible. Commissioning Manual, 05/

40 Configuring SIMOTION 3.2 Inserting SIMOTION into a project Communication with the programming device / PC via PROFIBUS (only for DP) 1. Select the PROFIBUS interface from the "Properties - PROFIBUS/MPI" dialog box and confirm your selection with "OK". 2. The connection to the programming device / PC is activated automatically and HW Config opens. Note The active state setting of the connection to the programming device / PC is only visualized in NetPro! Interconnection with the programming device / PC on PROFINET (only for DN) The "Properties - Ethernet Interface" dialog box is open. Figure 3-1 Properties of the Ethernet interface Program the following parameters in the "Properties - Ethernet Interface" dialog box: 1. Click "New". The "New Subnet Industrial Ethernet" dialog box opens. Rename the new subnet, or accept the default name by clicking "OK". 2. Select the new Ethernet subnet which is now displayed in the "Properties - Ethernet Interface" dialog box. 3. Define your addresses in the "IP address" and "Subnet mask" fields of the "Properties - Ethernet Interface" dialog box. Change to the "Network node" field and define whether you are going to use a router and, if yes, enter the router address. Confirm with "OK". 40 Commissioning Manual, 05/2009

41 Configuring SIMOTION 3.2 Inserting SIMOTION into a project 4. Select the PROFINET interface from the "Properties" dialog box and confirm your selection with "OK". 5. The connection to the programming device / PC is activated automatically and HW Config opens. Note The active state setting of the connection to the programming device / PC is only visualized in NetPro! Representation in HW Config SIMOTION is represented in HW Config. Figure 3-2 Image of a SIMOTION PN in HW Config Additional references You can find additional information on the subject of going online in SIMOTION Utilities & Applications. SIMOTION Utilities & Applications is provided as part of the SIMOTION SCOUT scope of delivery. Commissioning Manual, 05/

42 Configuring SIMOTION 3.3 Configuring the PROFIBUS DP interface (only DP) 3.3 Configuring the PROFIBUS DP interface (only DP) General information about PROFIBUS DP communication Definition of PROFIBUS DP PROFIBUS DP is an international, open field bus standard specified in the European field bus Standard EN Part 2. PROFIBUS DP is optimized for high-speed, time-sensitive data transfer at field level. Components communicating on PROFIBUS DP are classified as master and slave components. Master (active bus node) Components representing a bus master determine the data traffic on the bus and are therefore also referred to as active bus nodes. Slaves (passive bus nodes) These devices may only receive, acknowledge and return messages to the master if requested by the master. Examples: SINAMICS drives, I/O modules Note If a SIMOTION DP is operated as a passive PROFIBUS I-slave, the display, measuring functions and controller optimization engineering functions will be very slow. If possible, use the "active I-slave" setting for local commissioning (which does mean that an equidistance is no longer possible) and for complete commissioning, switch to "passive I- slave". Additional references You will find additional information about PROFIBUS DP in the SIMOTION Communication System Manual. 42 Commissioning Manual, 05/2009

43 Configuring SIMOTION 3.3 Configuring the PROFIBUS DP interface (only DP) Assignment of the PROFIBUS addresses in HW Config Assigning PROFIBUS addresses Assign a PROFIBUS address to all devices before you start networking these in order to enable intercommunication. Note All PROFIBUS addresses you assign must be unique on the PROFIBUS subnet. Information pertaining to the rules of communication on the PROFIBUS subnet is available in the SIMOTION Manual. Define the PROFIBUS address separately for each device on your programming device / PC in HW Config. Certain PROFIBUS DP slaves are equipped with an address switch. 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 are connected to the subnet as required. Recommended PROFIBUS address setting for SIMOTION in case of replacement or service: Reserve address "2" for a SIMOTION. This prevents redundancy of the addresses after SIMOTION is installed in the subnet with default settings (for example, when replacing a SIMOTION ). Assign addresses higher than "2" to any additional devices on the subnet. Commissioning Manual, 05/

44 Configuring SIMOTION 3.3 Configuring the PROFIBUS DP interface (only DP) Operating SIMOTION on PROFIBUS DP. PROFIBUS DP interface (X21) SIMOTION provides an interface for connecting to PROFIBUS DP. The interface supports transmission rates up to 12 Mbit/s. The X21 interface can be operated as a: DP slave, isochronous DP master, isochronous DP slave, not isochronous DP master, not isochronous MPI interface Both PROFIBUS DP interfaces are set by default for operation as master at address 2 at a transmission rate of 1.5 Mbit/s. The PROFIBUS DP network is automatically detected and generated for this setting. However, you can select other settings. Such user-specific settings must be configured in HW Config and NetPro. Note Communication with the SINAMICS Integrated of a is always equidistant. Here, the SIMOTION is the master and the SINAMICS Integrated drive is the slave. 44 Commissioning Manual, 05/2009

45 Configuring SIMOTION 3.3 Configuring the PROFIBUS DP interface (only DP) Creating a new PROFIBUS DP subnet The SIMOTION device is networked using SIMOTION SCOUT. Set up your userspecific bus parameters for the PROFIBUS interface when you configure the network. Note The actions outlined below only need to be taken if you have not selected an interface when integrating SIMOTION into the project (cf. chapter "Integrating SIMOTION into a project"). Next, interconnect the programming device / PC using NetPro with the device, see the chapter "Configuring the programming device / PC interface". 1. Double-click the "" entry in the Project Navigator in order to open HW Config. 2. Double-click the DP/MPI interface in the SIMOTION representation in HW Config. The "Properties - DP/MPI" dialog box opens. 3. Click "Properties" in the "General" tab to open the "PROFIBUS interface DP/MPI" dialog box. 4. Click "New" to open the "Properties - New PROFIBUS Subnet" dialog box. 5. Name the new subnet, and then enter its properties in the "Network settings" tab, for example, the transmission rate. 6. Click "OK" to accept the settings. The new subnet is now displayed in the "Properties - PROFIBUS interface DP/MPI" dialog box and is ready for being interconnected with the PROFIBUS DP interface. 7. Save and compile the changes. The PROFIBUS subnet you created is displayed as a graphic object in HW Config. Commissioning Manual, 05/

46 Configuring SIMOTION 3.3 Configuring the PROFIBUS DP interface (only DP) Setting the DP cycle and system cycle clocks All system clocks for SIMOTION DP are based on the DP cycle of SINAMICS Integrated, which must be set in HW Config. In HW Config, double-click the SINAMICS drive at the integrated PROFIBUS. The "DP Slave Properties" dialog box opens. You can synchronize the DP cycle of SINAMICS Integrated in the "Isochronous mode" tab. Table 3-1 Range of values for SIMOTION DP DP cycle Grid 1 ms ms The PROFIBUS DP interface of the SIMOTION DP supports operation at a DP cycle time 1 ms, at a resolution of ms. SINAMICS Integrated always runs in isochronous mode. The cyclic tasks of SIMOTION are therefore always in synchronism with SINAMICS Integrated. The set DP cycle of SINAMICS Integrated is displayed as "Bus cycle" in the "System Clocks -..." dialog box in SIMOTION SCOUT. Select the SIMOTION DP in the project tree, and then select the "Set system clocks" option in the "Target system" > "Expert" menu. The table below shows the ratios you can set for the system clocks of SIMOTION DP based on the DP cycle. Table 3-2 Possible factors between the system cycle clocks Servo cycle: Bus cycle IPO cycle: Servo cycle IPO2 cycle: IPO cycle 1 to 4, 8 1 to 6 2 to 64 The minimum servo cycle length that can be set is 2 ms. If you programmed the PROFIBUS DP interface for operation in isochronous master mode, you must synchronize its DP cycle with the DP cycle of SINAMICS Integrated in HW Config. The timebase for the system clocks is generated internally if the DP interface is operated in isochronous or non-isochronous master mode. SIMOTION does not have to synchronize itself with an external cycle. The PROFIBUS DP interface can also be operated in isochronous slave mode. In this constellation system clocks are based on the clock signals received at the slave interface. A substitute clock of a duration equivalent to the configured clock is generated internally if the isochronous slave interface has not received a clock signal. The clock settings are included in the project download to SIMOTION DP and are adjusted according to specification. At a PROFIBUS DP interface operated in isochronous slave mode you can also step down the clock ratio for synchronization with SINAMICS Integrated. This reduction of the clock ratio at the isochronous slave interface for synchronization with SINAMICS Integrated allows the operation of a DP cycle at the slave interface which is equivalent to an integer multiple SINAMICS Integrated. This reduction can be set up by setting an integer multiple of the SINAMICS Integrated DP cycle as the DP cycle for the DP interface (X21) in HW Config. The rule is checked in HW Config. 46 Commissioning Manual, 05/2009

47 Configuring SIMOTION 3.3 Configuring the PROFIBUS DP interface (only DP) Rules for SIMOTION DP Rules for synchronizing the system clocks You must adhere to the following rules when setting the DP cycle and SINAMICS cycle clocks: 1. The DP cycle must be an integer multiple of the current controller cycle. Error A01902 (2) is reported in the drive if this rule is violated. 2. The master application cycle (Tmapc), which corresponds to the servo cycle, must be an integer multiple of the speed controller cycle. Error A01902 (7) is reported in the drive if this rule is violated. The smallest-possible T mapc so results from the smallest common multiple of the DP cycle and the speed controller cycle. If the master application cycle = 1, this means that the DP cycle is also an integer multiple of the speed controller cycle. 3. The DP cycle must be an integer multiple of the basic cycles r0110[x] (DRIVE-CLiQ basic sampling rates). Error A01902 (13) is reported in the drive if this rule is violated. You can determine parameter r0110[x] using the expert list in SIMOTION SCOUT (select the "Control_Unit" from "SINAMICS_Integrated" in the Project Navigator, and then open the "Expert List" by selecting the "Expert" command from the shortcut menu). Note In addition to the rules mentioned, also observe the rules outlined below. These rules apply both to SIMOTION DP and to SIMOTION PN! An overview of errors reported by the SINAMICS Integrated is provided in the SINAMICS S Parameter Manual. Rules for SIMOTION DP The general rule for SIMOTION specifies that the DP cycle ( DP) forms the basic clock of the cycle system. All cycles longer than this basic clock must be an integer multiple of the basic clock. This rule also applies to SINAMICS cycles, if one of the successive cycles is longer than the basic clock: Speed controller p115[1] Flow controller p115[2] Setpoint channel p115[3] Position controller p115[4] Positioning p115[5] Technology controller (p0115[6]) Onboard I/O p0799 Terminal module I/O p4099 The corresponding cycle must be an integer multiple of the basic clock (DP cycle). Commissioning Manual, 05/

48 Configuring SIMOTION 3.3 Configuring the PROFIBUS DP interface (only DP) If any change to the DP cycle violates this rule you must also change the SINAMICS cycles. In order to change the cycles in the Expert list of SIMOTION SCOUT, select the "Control_Unit" from "SINAMICS_Integrated" in the Project Navigator, and then open the "Expert List" by selecting the "Expert" command from the shortcut menu. Example: A default value of 4 ms is set at the SINAMICS setpoint channel. If the DP cycle is to be set to 3 ms, the fact that an integer multiple value is required means that you will need to set 3 ms or 6 ms (for example) for the setpoint channel Operating the PROFIBUS interface (X21) as an MPI interface The X21 interface can also be operated as an MPI interface instead of a PROFIBUS DP interface. The typical (default) baud rate is 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/programming device 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 Additional references For more detailed information on MPI in relation to SIMOTION D, refer to the SIMOTION D4x5 Commissioning and Hardware Installation Manual. For general information on MPI, refer to the SIMOTION Communication System Manual. 48 Commissioning Manual, 05/2009

49 Configuring SIMOTION 3.4 Configuring PROFINET (only for PN) 3.4 Configuring PROFINET (only for PN) General information about PROFINET communication Overview PROFINET is an open component-based industrial communication system using Ethernet (IEC 61158) for distributed automation systems. The PROFINET interface supports operation of SIMOTION PN as IO controller and/or as intelligent device. PROFINET distinguishes between the controller and its assigned devices. Controller and devices form a PROFINET IO system, comparable to a master-slave system on PROFIBUS. SIMOTION PN supports the following PROFINET communication methods: RT IRT With IRT, a distinction is made between IRT with high flexibility and IRT with high performance. Additional references Additional information pertaining to PROFINET communication is available in the SIMOTION Communication System Manual. Commissioning Manual, 05/

50 Configuring SIMOTION 3.4 Configuring PROFINET (only for PN) Operating SIMOTION PN on PROFINET PROFINET interface (port X200, X201) SIMOTION PN provides a dual-port PROFINET interface (X200 and X201). The interface supports transmission rates as high as 100 Mbit/s. It can also be operated isochronous and equidistant. The autocrossing functionality means both crossed and uncrossed cables can be used A port has two integrated LEDs, a green LED and an orange LED. The following LED states can occur: Table 3-3 LED states of the LED on the port of the PROFINET interface LEDs Status Meaning Green LED off No connection to an active partner exists. LED on A connection to an active partner exists. Orange LED off No data is being exchanged. LED flashing Data is being exchanged over the port. The LED flashes irregularly depending on the data exchange, i.e. the LED does not flash with a specific frequency. Properties of PROFINET on SIMOTION PN SIMOTION PN on PROFINET supports the following properties PROFINET specifies operation at 100 Mbit/s. The minimum send cycle is 0.5 ms, and the maximum is 4 ms. The setting accuracy for the send cycle is 125 μs. The use of cycle reduction is possible for the. Detailed information concerning cycle reduction is available in the SIMOTION Communication System Manual. 50 Commissioning Manual, 05/2009

51 Configuring SIMOTION 3.4 Configuring PROFINET (only for PN) Initializing SIMOTION SIMOTION must be assigned an IP address and a device name in order to enable downloading of the project. This is performed online on the SIMOTION device using the socalled "node initialization". To perform the node initialization, the programming device / PC must be connected with the SIMOTION PN. SIMOTION SCOUT must be open. 1. Click the "Reachable nodes" button on the SIMOTION SCOUT toolbar. The newly opened "Reachable nodes" window shows the SIMOTION device as "bus node" with the address and a name. 2. Select the "Bus node" entry and open the "Edit Ethernet node..." function in the context menu. The "Edit Ethernet Node" dialog box opens. 3. Enter a name in the "Device name" field. 4. Click the "Assign name" button and confirm the displayed message with "OK." 5. Enter an appropriate IP address for the Ethernet subnet in the "IP address" field. 6. Enter an appropriate subnet mask for the Ethernet subnet in the "Subnet mask" field. 7. If required, enter the data for a network gateway. 8. Click "Assign IP Configuration". The entered data is assigned to the SIMOTION device. 9. Confirm the displayed message with "OK". 10. Click the "Close" button to close the "Edit Ethernet Node" window. 11. Click the "Update" button in the "Reachable Nodes" window. The SIMOTION device is now displayed as "Geraet_01" with the type designation of the device and the assigned IP address. 12. Click the "Close" button to close the "Reachable Nodes" window. Reading the IP address To fetch the IP address, the SIMOTION SCOUT must be in online mode. The IP address of SIMOTION PN can be viewed in SIMOTION SCOUT as follows: 1. Establish an online connection to the SIMOTION. 2. Right-click the SIMOTION device in SIMOTION SCOUT. 3. Select the "Target device > Device Diagnostics" command from the shortcut menu. The address is displayed as follows, for example: Figure 3-3 Reading the IP address Commissioning Manual, 05/

52 Configuring SIMOTION 3.4 Configuring PROFINET (only for PN) As an alternative, you can determine the IP address as follows: By accessing "Project" > "Reachable nodes" in SIMOTION SCOUT or By calling "Target system" > "Ethernet" > "Edit Ethernet node..." in HW Config and browsing to "Online reachable nodes". Note The MAC address is available on the rating plate on the front panel of the module. Changing the IP address, device name, network gateway Set the IP address, the subnet mask and, if necessary, the data for a gateway (router address) in order to enable communication over PROFINET with SIMOTION. If you want to change the properties in the PROFINET subnet, you can change them using the "Reachable nodes" function in SIMOTION SCOUT or in the HW Config. The "Reachable nodes" function in SIMOTION SCOUT is described in the section titled "Initializing SIMOTION ". To configure and transfer the properties in HW Config, proceed as follows: 1. Open your project in SIMOTION SCOUT. 2. Open HW Config. Double-click the PROFINET interface to open the "Properties" dialog box. 3. Click "Properties". The "Properties - Ethernet Interface" dialog box opens. 4. Click "New". The "New Subnet Industrial Ethernet" dialog box opens. Rename the new subnet, or accept the default name by clicking "OK". 5. Select the new Ethernet subnet which is now displayed in the "Properties - Ethernet Interface" dialog box. 6. Enter the required addresses in the "IP address" and "Subnet mask" fields of the "Properties - Ethernet interface" dialog. In the "Gateway" field, select whether or not you wish to use a router and, if you do, enter the router address. Confirm with "OK". 7. Close the "Properties" dialog by clicking "OK". 8. Save and compile the modified hardware configuration. 9. Download the new hardware configuration on PROFINET to your SIMOTION. 52 Commissioning Manual, 05/2009

53 Configuring SIMOTION 3.4 Configuring PROFINET (only for PN) Setting the send cycles and system clocks Prerequisite The SIMOTION system clocks (servo/ipo/ipo2) are based on the SINAMICS Integrated DP cycle or the PROFINET send cycle, depending on the PROFINET real-time class and the type of data transfer. The cycle clock source can be generated "internally" by the SIMOTION ; otherwise, it is obtained "externally" from the clock signals received at the PROFINET interface. Table 3-4 Basis for the SIMOTION system clocks/cycle clock source Real-time class in which the PROFINET interface is operated Data transfer Basis for the SIMOTION system clocks DP cycle (Integrated) PROFINET send cycle 1) RT communication X Internal IRT communication X Internal (high flexibility) Cycle clock source IRT communication The is the SYNC master X Internal (high performance) in the I/O system; synchronized data traffic takes place 2) The is the SYNC slave X External in the I/O system; Internal synchronized data traffic takes (as substitute value) place 2) No synchronized data traffic 2) X Internal 1) If the PROFINET send cycle forms the basis for the SIMOTION system clocks, the SINAMICS Integrated DP cycle and the servo cycle are equal. 2) Synchronized data traffic, e.g. by means of: - Controller-controller slave-to-slave communication - I/O device in separate I/O system Setting the DP cycle in HW Config Set the DP cycle of SINAMICS Integrated in HW Config. In HW Config, double-click the SINAMICS drive at the integrated PROFIBUS. The "DP Slave Properties" dialog box opens. You can synchronize the DP cycle of SINAMICS Integrated in the "Isochronous mode" tab. Table 3-5 Range of values for SIMOTION PN DP cycle Grid 1 ms ms SINAMICS Integrated always operates in isochronous mode. The cyclic tasks of SIMOTION are therefore always in synchronism with SINAMICS Integrated. Commissioning Manual, 05/

54 Configuring SIMOTION 3.4 Configuring PROFINET (only for PN) Setting the send cycle in HW Config The PROFINET send cycle always forms the basis for the SIMOTION cycles if the "IRT communication" real-time class is set and data are being transferred. Set the send cycle in the "Domain Management" dialog box of HW Config. Open this dialog by selecting the "Edit" > "PROFINET IO" > "Domain Management..." command in HW Config. The set PROFINET send cycle is displayed in SIMOTION SCOUT as "Bus cycle" in the "System Clocks -..." dialog box. Select the SIMOTION PN in the project tree, and then select the "Set system clocks" option in the "Target system" > "Expert" menu. The PROFINET interface supports send cycle times within the range 0.5 ms < send cycle < 4 ms. The maximum configurable resolution is ms. The table below shows which ratios you can set for the system clocks of SIMOTION PN based on the DP cycle of SINAMICS Integrated or on the PROFINET send cycle. Table 3-6 Possible factors for setting the system clocks Servo cycle: DP cycle/send cycle IPO cycle: Servo cycle IPO2 cycle: IPO cycle 1 to 4, 8 1 to 6 2 to 64 The minimum servo cycle length that can be set is 2 ms Rules for SIMOTION PN Rules for using the PROFINET send cycle If the PROFINET send cycle is the basis for the cycles, ensure that the DP cycle of the SINAMICS Integrated and the servo cycle are equal. The timebase for the system clocks are generated internally if the PROFINET interface is not operated with RT class IRT with high performance or IRT with high performance is set, but no data is being transferred. This even applies if the PROFINET interface with real-time class "IRT with high performance" is being operated as the synchronization master and data are being transferred. The SIMOTION device does not have to synchronize itself with an external cycle. The basis for system clocks is derived from the clock signals received at the PROFINET interface if this interface is operated as synchronization slave with RT class IRT with high performance. The SIMOTION device does not have to synchronize itself with this external clock. A substitute clock of a duration equivalent to the configured clock is generated internally if the PROFINET interface has not received a clock signal. The clock settings are included in the project download to the SIMOTION device and are adjusted according to specification. 54 Commissioning Manual, 05/2009

55 Configuring SIMOTION 3.4 Configuring PROFINET (only for PN) Rules for SIMOTION PN As a general rule for SIMOTION, the send cycle ( PN) forms the basic clock of the task system. All cycles longer than this basic clock must be an integer multiple of the basic clock. This rule also applies to SINAMICS cycles, if one of the successive cycles is longer than the basic clock: Speed controller p115[1] Flow controller p115[2] Setpoint channel p115[3] Position controller p115[4] Positioning p115[5] Technology controller (p0115[6]) Onboard I/O p0799 Terminal module I/O p4099 The corresponding cycle must be an integer multiple of the basic clock. If any change to the send cycle violates this rule you must also change the SINAMICS cycles. In order to change the cycles in the Expert list of SIMOTION SCOUT, select the "Control_Unit" from "SINAMICS_Integrated" in the Project Navigator, and then open the "Expert List" by selecting the "Expert" command from the shortcut menu. Example: A default value of 4 ms is set at the SINAMICS setpoint channel. If the send cycle is to be set to 3 ms, the fact that an integer multiple value is required means that you will need to set 3 ms or 6 ms (for example) for the setpoint channel. Note An overview of errors reported by the SINAMICS Integrated is provided in the SINAMICS S Parameter Manual. Commissioning Manual, 05/

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57 Commissioning (software) Overview of commissioning Prerequisites Prerequisites for commissioning the SIMOTION : The system has been connected and wired. The SIMOTION is switched on and started up (STOP state). SIMOTION SCOUT (with integrated STARTER) has been installed and started on the programming device / PC. Communication between the SIMOTION and the programming device / PC is configured. You have created a project and installed a SIMOTION in the project. Commissioning steps This chapter describes the steps in configuring the plant and testing the configured standalone drive and axis. The steps in commissioning are listed below in the order as recommended: 1. Configuring SINAMICS Integrated The integrated drive SINAMICS Integrated can be configured in offline or online mode: For information on offline configuration, refer to the section titled Configuring the system in offline mode (Page 59). All components and their order number must be known for the offline configuration. For information on online configuration, refer to the section titled Configuring the system in online mode (Page 73). The configuration in online mode allows you to upload all information of the connected DRIVE-CLiQ components to your user project. 2. For information on testing a configured drive, refer to the section titled Testing the configured drive using the drive control panel (Page 86). 3. For information on creating an axis, refer to the section titled Creating an axis (Page 88). 4. For information on testing a configured axis, refer to the section titled Testing the configured axis using the axis control panel (Page 90). 5. For information on integrating an additional encoder (optional), refer to the section titled Integrating additional encoders (optional) (Page 92). 6. For information on configuring drive-related I/Os, refer to the section titled Configuring drive-related I/Os (Page 95). 7. For information on optimizing the drive and controller, refer to the section titled Optimizing the drive and controller (Page 118). Commissioning Manual, 05/

58 Commissioning (software) 4.1 Overview of commissioning Observe the corresponding references. This chapter also contains additional configuration information, e.g. for vector drives, Safety Integrated, etc. Downloading projects/copying from RAM to ROM Please note the following behavior concerning SIMOTION SCOUT's online functions: Icon Function Effect Downloading the project to the target system Downloading the CPU/drive unit to the target device Downloading the CPU/drive unit to the programming device Copying RAM to ROM Downloads the programs to the SIMOTION device as well as the configuration for the SINAMICS Integrated. The configuration is only downloaded to the device selected in the project tree (which means that the function needs to be performed separately for each and SINAMICS Integrated). The unit configuration is downloaded to the programming device selected in the project tree (which means that the function needs to be performed separately for each and SINAMICS Integrated). 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 and SINAMICS Integrated). 58 Commissioning Manual, 05/2009

59 Commissioning (software) 4.2 Configuring the system in offline mode 4.2 Configuring the system in offline mode Overview Introduction You can decouple commissioning of the drive from the system engineering. This enables you to configure the system offline (in the office), e.g. configure the drive and create a virtual axis. In this way, a SIMOTION project can be developed to the point that there is a basic project specification (including a program). You can then download the finished project to the SIMOTION. Any errors that were made during configuration can be cleaned up during online operation (using a desired/actual comparison of the SINAMICS topology). Prerequisites for offline configuration All components and their order number must be known for the offline configuration. You created a project in SIMOTION SCOUT and added a SIMOTION to the project. You configured the communication between the programming device / PC and SIMOTION. Procedure Steps involved in offline configuring: Calling the Drive Wizard Configuring components Aligning the HW Config Downloading the project to SIMOTION, by means of the following options: Downloading to the target system Downloading to the CompactFlash Card Downloading incl. sources and additional data Note During offline configuration, you can configure Terminal Modules such as the TM15, for example. Commissioning Manual, 05/

60 Commissioning (software) 4.2 Configuring the system in offline mode Accessing the drive wizard Integrated drive SIMOTION features an integrated SINAMICS S120 drive (control unit) which is automatically included when you insert the SIMOTION in the Project Navigator. The integrated drive must be operated in equidistant, isochronous mode using PROFIdrivecompliant message frame types. The Drive Wizard for the integrated STARTER in SIMOTION SCOUT is available for the purpose of configuring the integrated drive and its associated modules (SINAMICS S120 Power Module, for example). Note Take note of all the necessary safety instructions and rules governing connections, which can be found in the latest SINAMICS S120 documentation on the SIMOTION SCOUT DVD. Procedure Select the "SINAMICS_Integrated" > "Configure drive unit" drive element in the Project Navigator to open the Drive Wizard. You can configure the following components: Power unit (e.g. SINAMICS S120 PM340 power module) Motor Encoder 60 Commissioning Manual, 05/2009

61 Commissioning (software) 4.2 Configuring the system in offline mode Configuring the components Procedure Note An overview of permissible configurations, quantity structures, and DRIVE-CLiQ topologies can be found in the SINAMICS S120 Commissioning Manual. 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 configuration stage. Commissioning Manual, 05/

62 Commissioning (software) 4.2 Configuring the system in offline mode 1. Enter a drive name in the "Drive Properties" dialog box and select the drive type (servo or vector). Figure 4-1 Drive properties 2. You can select the function modules and the control mode in the "Open-loop Control Structure" dialog box. Figure 4-2 Control-loop structure 62 Commissioning Manual, 05/2009

63 Commissioning (software) 4.2 Configuring the system in offline mode 3. In the "Power Unit" dialog, use the order number to select your power unit from the list. Figure 4-3 Selecting a power unit 4. Select in the "Power unit supplementary data" dialog the component added to the power unit. The selection of the component depends on the construction type. DP with PN: The SIMOTION snapped directly onto the PM340 power module CUA31 or CUA32: The CUA3x snapped directly onto the PM340. The is mounted individually on a mounting plate. The is connected to the CUA3x using a DRIVE-CLiQ cable. Figure 4-4 Selecting the mounting type Commissioning Manual, 05/

64 Commissioning (software) 4.2 Configuring the system in offline mode 5. In the next dialog, select the motor and, where applicable, the motor type: 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 4-5 Selecting a motor Note A motor with a DRIVE-CLiQ interface is directly connected to the Power Module. This means that the motor sensor and temperature signals as well as the electronic type plate data, such as the unique identification number and rated data (voltage, current and torque), are transferred directly to the Control Unit. These motors feature integrated encoder evaluation. 64 Commissioning Manual, 05/2009

65 Commissioning (software) 4.2 Configuring the system in offline mode 6. Select a motor holding brake (if installed). Figure 4-6 Selecting a motor holding brake Commissioning Manual, 05/

66 Commissioning (software) 4.2 Configuring the system in offline mode 7. Select the encoder order number in the "Encoder selection by motor order number" if using a motor that is not equipped with a DRIVE-CLiQ interface. Figure 4-7 Selecting the encoder order number Note If required, you can configure a second or third encoder in the "Encoder" dialog. You can transmit a maximum of 2 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 box for selecting Encoder 1 is grayed out and, therefore, inactive). 8. In the next dialog, select the PROFIdrive message frame. The following message frames can be used, for example, in conjunction with SINAMICS S120 drives: SIEMENS message frame 105, PSD-10/10: Dynamic life sign, torque reduction, encoder data for an encoder, dynamic drive control (DSC) SIEMENS message frame 106, PSD-11/15: Dynamic life sign, torque reduction, encoder data for two encoders, dynamic drive control (DSC) 66 Commissioning Manual, 05/2009

67 Commissioning (software) 4.2 Configuring the system in offline mode Advantages of DSC (compared to a position controller in the control unit): Higher Kv (position controller gain) possible Larger bandwidth and consequently higher dynamic response Shorter response times for disturbance characteristic The DSC dynamic drive control can be used for the SIEMENS message frame 105, PSD- 10/10 and SIEMENS message frame 106, PSD-11/15. The DSC is activated by default for the configuration of the axis using the Drive Wizard. Detailed information for the various message frame types can be found in the Motion Control, TO Axis Electric / Hydraulic, External Encoder Function Manual. Figure 4-8 Selecting the PROFIdrive message frame A "Summary" dialog box opens with a listing of all settings after you completed all settings in the Drive Wizard. You can now choose to activate your settings by clicking "Finish", or to return to the component configuration for further editing. Commissioning Manual, 05/

68 Commissioning (software) 4.2 Configuring the system in offline mode Figure 4-9 Finishing the drive The configured drive is displayed in the Project Navigator. An overview of your configured SINAMICS components is available in the "SINAMICS_Integrated" > "Topology" dialog. In the next step, HW Config alignment must be carried out for the configured drive component. 68 Commissioning Manual, 05/2009

69 Commissioning (software) 4.2 Configuring the system in offline mode Aligning HW Config After having completed the configuration of all SINAMICS components, align the data with HW Config. Proceed as follows: 1. Open the "Configuration" entry in the "SINAMICS_Integrated" tree in the Project Navigator. The "SINAMICS_Integrated - Configuration" dialog box opens with a list of configured drive objects. The question marks in the I/O address fields indicate that you have not yet defined the I/O addresses of the drive objects. Figure 4-10 Configuration prior to HW Config alignment Note Drive objects without address must be positioned at the end of the list, for otherwise it is not possible to align HW Config ("Align with HW Config"). To move the order of a drive object without address, select the associated drive object and move it downwards using the arrow key. 2. Click "Align with HW Config" in order to assign addresses to the configured components. The addresses are written to HW Config. Figure 4-11 Configuration after HW Config alignment Commissioning Manual, 05/

70 Commissioning (software) 4.2 Configuring the system in offline mode Note If the message frames for drive objects (Control Unit, Drive, Terminal Modules, etc.) change, you must perform HW Config alignment again. The addresses are not updated automatically Downloading a project created offline to the target system Procedure 1. Save and compile the project. 2. Go online to SIMOTION. 3. Select the "Download project to target system" command to download the project to SIMOTION. The connection to SINAMICS Integrated is activated automatically. 4. Execute the "Copy RAM to ROM..." function on the and SINAMICS Integrated. This saves the project on the CompactFlash Card, meaning that it does not need to be reloaded after switching off and on again. Drive programming and commissioning is completed. You can now test the drive using the drive control panel. Note Online access to SINAMICS Integrated is not possible if HW Config is not loaded at the time you initially connect to the target system. Download the data to HW Config in order to enable online access to SINAMICS Integrated. 70 Commissioning Manual, 05/2009

71 Commissioning (software) 4.2 Configuring the system in offline mode Loading a project created offline to the CompactFlash Card Procedure You can use a card reader to write the entire project to the CompactFlash Card, even in offline mode. In SIMOTION SCOUT, you can call the "Download to the file system" function in the context menu of the SIMOTION device. 1. Save and compile the project. 2. Switch off the SIMOTION. 3. Remove the CompactFlash Card and insert it in a card adapter. The card adapter must be connected to a programming device/pc. 4. In the SCOUT project, select the SIMOTION device that you want to download to the CompactFlash Card. 5. Click "Download to the file system" in the context menu. A dialog box opens. 6. In the "Download to the file system" dialog, select the "Save normal" option and click the "Select target" button. 7. Select the target drive. 8. Confirm your entries with "OK". The data will be written to the CompactFlash Card. 9. Remove the CF card and insert it in the slot. 10. Switch on the. The starts with the downloaded project. Note The components' firmware is automatically updated, depending on the FW version on the SINAMICS components and on the CompactFlash Card. During an FW update, please take note of the messages and alarms in the SIMOTION SCOUT detail window. An FW update on the SIMOTION is signaled by the RDY LED flashing yellow, while on the DRIVE-CLiQ components (TM, SMC, etc.) it is signaled by the RDY LED flashing red/green. FW update running: RDY LED flashes slowly (0.5 Hz) FW update complete: RDY LED flashes quickly (2 Hz) Go offline once all the FW updates are complete, then switch the 24 V supply for the upgraded initialization components off/on. Commissioning Manual, 05/

72 Commissioning (software) 4.2 Configuring the system in offline mode Downloading a project, including sources and additional data Overview In the case of SIMOTION V4.1 SP2 and higher, it is possible to download additional data (e.g. sources) to the target device when saving a project to the CompactFlash Card or downloading to the. These data are 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 programming device, this must be specified in the project under "Options" > "Settings" > "CPU download" > "Save supplementary 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 placed a project on your PC/programming device. This project is not consistent with the project on the in the system. In order to analyze the differences, perform an object comparison via "Start object comparison". You have the following options in terms of re-establishing consistency: In the object comparison, it is possible to establish consistency in sources and technology objects on an object-granular basis. Consistency can be established for the whole Control Unit by loading the CompactFlash Card via "Target system" > "Load" > "Load to PG". Additional references Detailed information on downloading data to the target device can be found in the SIMOTION Basic Functions Function Manual. 72 Commissioning Manual, 05/2009

73 Commissioning (software) 4.3 Configuring the system in online mode 4.3 Configuring the system in online mode Overview Introduction You can configure the plant in online mode after having completed its wiring. You can use the "Automatic configuration" function to load the SINAMICS components connected via DRIVE-CLiQ to your programming device/pc. However, this functionality is only available within the initial commissioning phase. 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). Prerequisites for online configuration You created a project in SIMOTION SCOUT and added a SIMOTION to the project. You configured the communication between the the programming device / PC and SIMOTION. Your system has been installed and wired. Procedure Steps involved in offline configuring: Establishing the online connection Starting automatic configuration Editing SINAMICS components Aligning HW Config Downloading the project to SIMOTION Commissioning Manual, 05/

74 Commissioning (software) 4.3 Configuring the system in online mode Establishing the online connection The procedure for an initial commissioning follows. To perform an online configuration, you must establish an online connection to the SIMOTION. In this case, no connection can yet be established to SINAMICS Integrated. An appropriate message is output. Once the hardware configuration has been loaded into 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. Select the SIMOTION device in the Project Navigator. Note Ensure that you use the "Download to the target device" function rather than "Download to the target system". An automatic commissioning is no longer possible after "Download to the target system". If "Download to the target system" has been used, "Restore factory settings" must be performed on the drive element in order to start an automatic commissioning afterwards. 4. Use the "Download to the target device" function to download the SIMOTION device into the target device. The connection to SINAMICS Integrated is activated automatically. You can now run the automatic configuration at SINAMICS Integrated. For details, refer to the section titled Starting automatic configuration (Page 75). Additional references Further information about establishing an online connection to the programming device / PC is contained in the following documentation: SIMOTION SCOUT Configuration Manual SIMOTION SCOUT Online Help In the FAQ for SIMOTION Utilities & Applications SIMOTION Utilities & Applications is provided as part of the SIMOTION SCOUT scope of delivery. 74 Commissioning Manual, 05/2009

75 Commissioning (software) 4.3 Configuring the system in online mode Starting automatic configuration Prerequisites You activated the online connection to SINAMICS Integrated. You have not yet configured any drive objects. The default settings of SINAMICS Integrated were activated. Right-click SINAMICS Integrated" and select the "Target device" > "Restore defaults" command from the shortcut menu in SIMOTION SCOUT in order to restore the factory settings. Procedure 1. Open the "Automatic Configuration" dialog box by selecting the "SINAMICS_Integrated > Automatic configuration" command in the Project Navigator. Figure 4-12 Starting automatic configuration 2. Click "Start automatic configuration". The "Drive Object Type" dialog box opens. Figure 4-13 Selecting the drive object type 3. Select either a servo or a vector drive object. Commissioning Manual, 05/

76 Commissioning (software) 4.3 Configuring the system in online mode 4. Click "Close" to complete automatic configuration. The configuration data is uploaded (Upload to PG) automatically as soon as automatic commissioning is completed. Note The components' firmware is automatically updated, depending on the FW version on the SINAMICS components and on the CompactFlash Card. During an FW update, please take note of the messages and alarms in the SIMOTION SCOUT detail window. An FW update on the SIMOTION is signaled by the RDY LED flashing yellow, while on the DRIVE-CLiQ components (TM, SMC, etc.) it is signaled by the RDY LED flashing red/green. FW update running: RDY LED flashes slowly (0.5 Hz) FW update complete: RDY LED flashes quickly (2 Hz) Go offline once all the FW updates are complete, then switch the 24 V supply for the upgraded initialization components off/on. 5. Click "Close" to exit automatic configuration. Figure 4-14 Automatic configuration completed 6. Execute the "Copy RAM to ROM..." function on the and SINAMICS Integrated. This saves the project on the CompactFlash Card, meaning that it does not need to be reloaded after switching off and on again. 76 Commissioning Manual, 05/2009

77 Commissioning (software) 4.3 Configuring the system in online mode Result The DRIVE-CLiQ components loaded to the user project by means of automatic configuration are displayed in the project navigator. Figure 4-15 Project Navigator with the downloaded DRIVE-CLiQ components You must then define the axis message frame and, if necessary, edit the SINAMICS components (e.g. components without a DRIVE-CLiQ interface, such as an encoder connected to the onboard encoder interface). See also Editing SINAMICS components (Page 78) Commissioning Manual, 05/

78 Commissioning (software) 4.3 Configuring the system in online mode Editing SINAMICS components Prerequisites You have uploaded all connected DRIVE-CLiQ components to the user project. You shut down the connection to the target system (offline mode). Procedure Now go ahead and adapt your components to suit the application. Run the wizards for all DRIVE-CLiQ components to be adapted and (if necessary) configure the motor, encoder, and process data message frames (PROFIdrive message frame type). This procedure corresponds with the description in chapter "Configuring the system in offline mode". The amount of editing work involved 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. Note If only the message frame type needs to be selected for the edit, you can also set this in the "Configuration" screen form of the drive element. HW Config alignment is then required. See also Configuring the system in offline mode (Page 59) Aligning HW Config The procedure you need to follow for carrying out HW Config alignment is described in the section titled Aligning HW Config (Page 69) Download the project to SIMOTION After having aligned HW Config, download the configuration to SINAMICS Integrated. 1. Save and compile the project. 2. Go online to SIMOTION. 3. Select the "Download project to target system" command to download the project to SIMOTION. The connection to SINAMICS Integrated is activated automatically. 4. Execute the "Copy RAM to ROM..." function on the and SINAMICS Integrated. This saves the project on the CompactFlash Card, meaning that it does not need to be reloaded after switching off and on again. Drive programming and commissioning is completed. You can now test the drive using the drive control panel. 78 Commissioning Manual, 05/2009

79 Commissioning (software) 4.4 Additional information on configuring the SINAMICS Integrated 4.4 Additional information on configuring the SINAMICS Integrated Settings for DP slave properties Settings in HW Config Depending on the cycle clock ratios (bus cycle, servo cycle) and the drive used, it may be necessary to adapt the properties of the DP slave (SINAMICS Integrated) on the PROFIBUS Integrated. Open HW Config. Double-clicking the SINAMICS Integrated enables you to display and, if required, change the properties of the DP slave on the "Isochronous Mode" tab. Possible changes include: Synchronizing the drive to the equidistant DP cycle The SINAMICS Integrated on a 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 set (setting is made in "Context Menu of the " > "Set System Cycle Clocks" in the project tree). Provided that the DP cycle is not scaled down to the servo cycle, the master application cycle will always be the same as the DP cycle. Commissioning Manual, 05/

80 Commissioning (software) 4.4 Additional information on configuring the SINAMICS Integrated Changing the DP cycle (TDP) It may be necessary to adapt the DP cycle, depending on the requirements placed on the quantity structures and response times. (Also refer to the SIMOTION Basic Functions Function Manual). Additionally, the minimum DP cycle for vector drives depends on the speed controller cycle, which in turn depends on the type of device used. This means that, particularly in the case of vector drives, the DP cycle must be checked and changed if necessary (refer to the section titled Using vector drives (Page 81)). 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 for devices in chassis format depends on the type of device used. Figure 4-16 HW Config - settings Additional references For additional information, please refer to the SINAMICS S120 Function Manual SIMOTION Basic Functions Function Manual 80 Commissioning Manual, 05/2009

81 Commissioning (software) 4.4 Additional information on configuring the SINAMICS Integrated 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 for drives in chassis format depend on the type of device used. Therefore, we recommend adopting the following procedure when using a vector drive with the SIMOTION. Procedure 1. Open HW Config. Double-clicking the 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. For the current controller cycle, use 375 µs for devices in chassis format and 500 µs for the PM For TDP, enter an integer multiple of the speed controller cycle. For a drive on the SINAMICS Integrated, TDP must be >= TO in all cases. 4. Enter TMAPC = TDP (exception: You are working with cycle reduction; i.e. servo cycle > DP cycle). 5. Use the "Target system" > "Load" > "Project to target system" menu command to download the parameterization to the SIMOTION. 6. Once the download has been successfully completed, you should determine the drive's current and speed controller cycles from the expert list for the drive, as cycles 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 list are different to the cycles used in steps 2 and 3, you will have to repeat the steps using the most up-to-date values for the current and speed controller cycles. Table 4-1 Vector drive Example Vector drive (chassis format) Current controller cycle = 375 µs Speed controller cycle = 1.5 ms Vector drive (PM340) Current controller cycle = 500 µs Speed controller cycle = 2 ms Settings TI = TO = At least 375 µs TDP = 1.5 ms (... or 3 ms, or 6 ms...) TMAPC = TDP For the SIMOTION, a minimum of 2 ms is recommended for the servo cycle. For this reason, set TMAPC = TDP = 3 ms or higher. TI = TO = At least 500 µs TDP = 2 ms (... or 4 ms, 8 ms...) TMAPC = TDP Note Vector drives in chassis format can also be operated with a current controller sampling time of 400 µs (among other settings). Commissioning Manual, 05/

82 Commissioning (software) 4.4 Additional information on configuring the SINAMICS Integrated In a SIMOTION context, the following should be considered: A current controller sampling time of 400 µs is only possible if a CU310/CU320 is used for control purposes, and if this is not operated isochronously via PROFIBUS/PROFINET on SIMOTION D. If the bus is operated isochronously, only cycles with an integer multiple of 125 µs are possible (instead of 400 µs, so 375 µs or 500 µs, for example). The PROFIBUS Integrated of a is always isochronous. This means that a current controller sampling time of 400 µs is not possible. With CU parameter p0092 = 1, the sampling times are preassigned in a way that enables isochronous operation with a control system. Additional references Additional information on quantity structures and cycle clock settings can be found in the SINAMICS S120 Function Manual Setting the time of day Time of day on SIMOTION (real-time clock) SIMOTION features an integrated real-time clock. All events on a module (alarms, messages, etc.) are "time-stamped" on the basis of the time shown by this real-time clock. To set the clock from SIMOTION SCOUT, select the 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 counter) For SINAMICS S120 Control Units and the SINAMICS Integrated on a SIMOTION, faults and warnings are "time-stamped" on the basis of the system runtime. This means that events are recorded in terms of operating hours rather than in terms of 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. The value is reset once 86,400,000 ms (24 hours) have passed. p2114[1] indicates the system runtime in days. The counter value is saved when the power is switched off. After the drive unit has been switched on, the counter continues to run with the value stored when the power was last switched off. 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" on the basis of a time of day, "Time-stamp operating hours" needs to be changed to "Time-stamp UTC format" as described below. 82 Commissioning Manual, 05/2009

83 Commissioning (software) 4.4 Additional information on configuring the SINAMICS Integrated Setting the time of day on SINAMICS Changing to UTC format CU parameter p3100 can be used to change the time-stamping mode from operating hours to UTC format. p3100 = 0: Time stamp based on operating hours p3100 = 1: Time stamp based on UTC format (UTC: Universal Time Coordinates) According to its definition, UTC time begins at 00:00:00 on 01/01/1970 and is expressed in days and milliseconds. Displaying the current UTC time in the drive system p3102[0]: Milliseconds p3102[1]: Days SIMOTION can transfer the time of day to the drive using a PING mechanism. This is only possible, however, if the SIMOTION format for the time of day (RTC, Real-Time Clock) is converted to UTC format. To compensate for deviations between the SIMOTION and SINAMICS clocks, the time of day must be reset on a regular basis (e.g. hourly). When doing this, please note the following: "Time/date to be set" is after "Time/date on SINAMICS": Time and date are tracked on SINAMICS. "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 if the time of day is reset. Additional references For more information on this topic, refer to the Online Help. There is also a sample program in SIMOTION Utilities & Applications. SIMOTION Utilities & Applications is provided as part of the SIMOTION SCOUT scope of delivery SINAMICS diagnostic buffer The SINAMICS Integrated diagnostic buffer can be displayed in SIMOTION SCOUT for SIMOTION version V4.1 SP2 and higher. To do this, select the SINAMICS Integrated in the project tree, followed by "Target System" > "Device Diagnostics". In addition, the SINAMICS diagnostic buffer entries are displayed in the device diagnostics. Here, all diagnostic buffer entries are displayed first, followed by those for the SINAMICS Integrated. The start of the SINAMICS Integrated diagnostic buffer entries is indicated by the following entry: >>>>>> Start of SINAMICS Integrated diagnostic buffer, station address = x <<<<<< You also have the option of viewing the SIMOTION and SINAMICS Integrated diagnostic buffers via IT DIAG. Commissioning Manual, 05/

84 Commissioning (software) 4.4 Additional information on configuring the SINAMICS Integrated 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 SINAMICS S120, configure the axis message frames for data exchange (see Configuring the system in offline mode (Page 59)). In addition to cyclic data exchange, PROFIdrive drive units feature 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 "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 while cyclic communication is taking place 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: Only one "write/read data set" operation can be performed at any one time on a drive unit (e.g. SINAMICS S120 Control Unit or 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 system. (for SIMOTION, this is a maximum of 8 jobs at a time). In the case of acyclic data exchange with SINAMICS drives, this means you will have to coordinate the write/read jobs with one another (buffer management). An interlock must be set in order to prevent the application or different parts of the application from sending overlapping jobs to the same PROFIdrive drive unit. 84 Commissioning Manual, 05/2009

85 Commissioning (software) 4.4 Additional information on configuring the SINAMICS Integrated 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 undertaking coordination tasks commonly associated with acyclic communication. The library does not coordinate access to the system functions (_ReadRecord/_WriteRecord/_readDriveParameter/_writeDriveParameter/, etc.), but instead expands the range of functions available for frequently requested tasks, such as time-of-day synchronization. SIMOTION Utilities & Applications is provided as part of the SIMOTION SCOUT scope of delivery. The functions available in the DP V1 library include: Buffer management (coordination of a number of parallel DP V1 services) StartUp (function for coordinating startup of the SINAMICS drive with SIMOTION) TimeSync (time-of-day 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 errors and warnings from the drive) Control properties and performance features With a few exceptions, the integrated drive control of the SIMOTION has the same control properties and performance features as the SINAMICS S120 CU310 Control Unit. We would particularly like to draw your attention to the following points: The SINAMICS Integrated does not feature a basic positioner (EPOS). EPOS functionality is provided by SIMOTION technology functions. It is not possible to connect a BOP20 Basic Operator Panel to the SIMOTION. NOTICE With the SIMOTION, the drive must not be reset using the expert list of the Control Unit in parameter p972 (drive unit reset). Doing so will lead to a SIMOTION malfunction, at which the RDY, RUN/STOP, and SF/BF LEDs will glow red. In this fault situation, the SIMOTION must be switched off and on again. Commissioning Manual, 05/

86 Commissioning (software) 4.5 Testing the configured drive using the drive control panel 4.5 Testing the configured drive using the drive control panel You can test a configured drive using the drive control panel where you can define a speed value by setting a scaling factor. The drive control panel should only be used for commissioning. Prerequisites The project has been downloaded to the target system. SIMOTION SCOUT is in online mode. The drive is not in use by a current project in RUN mode. WARNING Make sure that the drive test does not pose any risk to persons. Testing the drive using 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 4-17 Drive control panel 2. To display the control range and axis diagnostics, click the "Show/hide control range" and "Show/hide diagnostics area" buttons. 86 Commissioning Manual, 05/2009

87 Commissioning (software) 4.5 Testing the configured drive using the drive control panel 3. Click "Assume control priority". The "Assume Control Priority" dialog box opens. Figure 4-18 Assuming control priority 4. Read the notes and confirm these with "Accept". 5. Activate the "Enables" checkbox to enable the drive. All enables are now set with the exception of ON/OFF1. 6. Enter your setpoint in the input field and shift the scaling to 0% as safety setting. Figure 4-19 Entering the setpoint 7. Click the "Drive On" button. The "Enable is set" LED lights up in green color. The drive starts moving as you move the slider towards the right side. The current motor speed is displayed in "Actual". 8. Click "Drive Off" to stop the drive after you completed the test. 9. Deactivate the enable signal and click "Give up control priority" to deactivate controlling at the programming device / PC. Commissioning Manual, 05/

88 Commissioning (software) 4.6 Creating an axis 4.6 Creating an axis Overview The SIMOTION SCOUT Engineering System can be used to insert axes in your project. 1. Start a session of the Axis Wizard in order to configure the axes and interconnect these with the SINAMICS Integrated drive. 2. Following this, select "SINAMICS_Integrated" in the project navigator and deactivate the "Connect Online" option in the context menu. This only downloads the project to the SIMOTION. Provided you have completed configuration at the drive end, we strongly recommend that you deactivate the SINAMICS Integrated so that work can be carried out more quickly. 3. Insert your user programs into the project. 4. Compile the project and download it to SIMOTION. Note Note that only one real axis can be used on a SIMOTION. Creating an axis using the Axis Wizard Axes are integrated as technology objects (TOs) in SIMOTION. Create the axis with corresponding settings under the SIMOTION and then interconnect it with SINAMICS Integrated. How to insert an axis: 1. Double-click the "Axis > Insert Axis" entry in the Project Navigator. This opens the Axis Wizard. Figure 4-20 Inserting an axis 2. Name the axis TO in the "Insert Axis" dialog box, select the technology and save and confirm your entries with "OK". 88 Commissioning Manual, 05/2009

89 Commissioning (software) 4.6 Creating an axis 3. Continue the Axis Configuration Wizard and enter your system settings until the "Drive Assignment" dialog box opens. 4. Click "Align SINAMICS devices..." to open the "Device Alignment" dialog box. 5. Select the drive to be aligned (SINAMICS Integrated) in this dialog box and then click "Align". The addresses are assigned to the configured components and entered in HW Config. Note This device alignment is only necessary if not already done in the course of drive commissioning. This shows that no interconnectable drive of the SINAMICS Integrated type is displayed. Figure 4-21 Assigning a drive 6. Select a drive unit in the "Drive Assignment" dialog box. Normally only a SINAMICS Integrated drive will be offered. Exception: A has been configured, for example, with a hydraulic axis. You have already defined the message frame type in the previous steps and so only need to accept it. To do this, click the "Accept data from the drive" button to transfer the SINAMICS Integrated values in the axis wizards. 7. Select the encoder from the "Encoder Assignment" dialog box and then adapt its properties. Click the "Accept data from the drive" button to transfer the SINAMICS Integrated values in the axis wizards. Note For motors with DRIVE-CLiQ interface, a "Accept data from the drive" automatically transfers the determined drive and encoder data (e.g. encoder type). This requires that the data has already been fetched from the attached devices. Namely, an offline configuration has already been used to establish an online connection or an online configuration has been performed. 8. Complete the Axis Wizard session. The configured axis is displayed in the Project Navigator. After downloading it to the target system, you can test the axis using the axis control panel. Commissioning Manual, 05/

90 Commissioning (software) 4.7 Testing the configured axis using the axis control panel 4.7 Testing the configured axis using 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: Testing all system components before the axis movement is controlled by a program Testing as to whether you can move the axis using the axis control panel if a fault is detected Moving the axes for tuning purposes (controller tuning) Executing active homing Setting and resetting the axis enable signal Testing a connected axis Prerequisites Prerequisites for testing: The project has been downloaded to the target system. SIMOTION SCOUT is in online mode. The mode selector switch is at STOPU: Recommendation: Operate the mode selector switch via SIMOTION SCOUT only ("Target system" > "Control operating mode"). 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 4-22 Axis control panel 2. To display the control range and axis diagnostics, click the "Show/hide control range" and "Show/hide diagnostics area" buttons. 90 Commissioning Manual, 05/2009

91 Commissioning (software) 4.7 Testing the configured axis using the axis control panel 3. Click "Assume control priority". Confirm the next message with "Yes" in order to set the controller to STOPU state. Note You must assume control priority in order to move the axis using the programming device / PC. You can always stop the axis by pressing the SPACEBAR. 4. The "Assume Control Priority" dialog box opens. Figure 4-23 Assuming control priority 5. Read the notes and confirm these with "Accept". 6. To enable the axis, click "Set/reset enables". Confirm the "Set Axis Enable" dialog box with "OK". 7. To traverse the axis, click the "Position-controlled traversing of the axis" button. 8. Enter a velocity. 9. Click "OK" to confirm the displayed "Set Axis Enable" window. 10. Click the "Start motion" button to traverse the axis. You can monitor the traversing motion at the velocity and position entries. Use the "Stop motion" button to stop the axis motion again. 11. Click "Set/reset enables" to remove the enable. Confirm the "Reset Axis Enable" dialog box with "OK". 12. Click "Give up control priority" to deactivate axis control at the programming device / PC. You can no longer control the axis at the programming device / PC if this state is set. Commissioning Manual, 05/

92 Commissioning (software) 4.8 Integrating additional encoders (optional) 4.8 Integrating additional encoders (optional) General information SIMOTION provides the option of integrating and configuring further encoders in addition to the motor encoder. The following encoders are supported for operation with SIMOTION : Encoders with DRIVE-CLiQ interface Encoders connected to SIMOTION via the onboard encoder interface (X23) Encoders connected to SIMOTION using an SMx module Encoders connected using PROFIBUS or PROFINET Prerequisite SIMOTION features a DRIVE-CLiQ X100 interface for connecting an encoder. An additional encoder can be connected, for example, using the on-board encoder interface (X23). Configuring two encoders The second encoder can be used at SIMOTION, for example, as: A 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 may enable improved smoothing of mechanical influences. If you use a second encoder as a machine encoder, you can work with the encoder changeover function. An external encoder You can use the external encoder for recording an external master value, for example. Configuring tasks Encoders connected via PROFIBUS or PROFINET are configured for SIMOTION only. Encoders connected using SMx, DRIVE-CLiQ or the onboard encoder interface, must be configured for the drive (SINAMICS Integrated) and SIMOTION. Configure this additional encoder on drive side (SINAMICS Integrated) and in SIMOTION: 1. For information on configuring a second encoder on the SINAMICS drive, refer to the section titled Configuring a second encoder on the SINAMICS drive (Page 93). 2. For information on configuring a second encoder for a TO axis in SIMOTION, refer to the section titled Configuring a second encoder for a TO axis in SIMOTION (Page 94). 3. For information on configuring an external encoder in SIMOTION, refer to the section titled Configuring external encoders in SIMOTION (Page 94). These steps in configuring are described in the next section. 92 Commissioning Manual, 05/2009

93 Commissioning (software) 4.8 Integrating additional encoders (optional) Configuring a second encoder on the SINAMICS drive Prerequisite You configured the drive with an encoder in the Drive Wizard. Procedure 1. Open the "Configuration" entry of your drive by selecting the "SINAMICS_Integrated" > Drives" command in the Project Navigator. The "Configuration" dialog box opens. 2. Click "Configure DDS..." to open the Drive Wizard. 3. Step the Drive Wizard forward until the "SINAMICS_Integrated - Encoders" dialog box opens. 4. Select the "Encoder 2" option in this dialog. The dialog box displays a list of available encoders. 5. Select for "encoder evaluation": SMx for the encoder connection using DRIVE-CLiQ / SMx DP (or PN) for the encoder connection using the onboard encoder interface Figure 4-24 Selecting the internal encoder interface 6. Select the connected encoder and confirm with "Continue". 7. In the "Configuration - SINAMICS Integrated - PROFIBUS (drive) Process Data Exchange" dialog box, select a message frame that supports the transmission of two encoder values (e.g. SIEMENS message frame 106, PSD-11/15). 8. Click "Continue" to complete the Drive Wizard. 9. Click "Transfer to HW Config" in the "SINAMICS_Integrated - Configuration" dialog box in order to align HW Config. The drive is configured for operation with two encoders. Commissioning Manual, 05/

94 Commissioning (software) 4.8 Integrating additional encoders (optional) Configuring a second encoder for a TO axis in SIMOTION Prerequisites You have configured a drive with two encoders as specified in Section Configuring a second encoder on the SINAMICS drive (Page 93). The set message frame supports the transmission of two encoder values. The configuration of the PROFIdrive message frames has been aligned with HW Config. Procedure 1. In the Project Navigator, open the Axis Wizard of the axis. 2. In the "Drive Assignment" dialog box, select the same message frame that you have already used to configure the second encoder on the SINAMICS Integrated or on the "SINAMICS Integrated > Configuration" screen form (e.g. SIEMENS message frame 106, PZD-11/15). 3. Complete the Axis Wizard session. You have configured a second encoder for an axis TO in SIMOTION. The set message frame type now allows you to use the value of a second encoder Configuring external encoders in SIMOTION An external encoder allows you to determine the position values of a drive without an associated axis. Prerequisite Encoder using PROFIBUS/PROFINET You have used HW Config to configure an encoder on the PROFIBUS or PROFINET. Two different possibilities are available for the encoder connection: Encoder interconnection using a PROFIdrive message frame (encoder with message frame type 81) Encoder interface as a direct value in the I/O area Detailed information can be found in the SIMOTION TO Axis, Electric / Hydraulic, External Encoder Function Manual Encoder on the drive You have created a drive with two encoders and the corresponding axis. A PROFIdrive message frame, which supports the transfer of 2 encoder values, must be configured for the axis. The second encoder value should be used as the "external encoder". This procedure is described below. 94 Commissioning Manual, 05/2009

95 Commissioning (software) 4.9 Configuring drive-related I/Os Procedure 1. Open the wizard for configuring an external encoder by selecting the "External Encoders" > "Insert external encoder" folder in the Project Navigator. 2. Assign a name in the "Inserting an external encoder" screen form and, if required, enter the author and version. 3. Execute the wizard for the encoder configuration and enter the appropriate values in the screen forms. The external encoder is configured and uses the second value, which is transferred by means of the selected PROFIdrive message frame. Additional references Detailed information for the external encoder is contained in the SIMOTION SCOUT TO Axis, Electric/Hydraulic, External Encoder Function Manual. 4.9 Configuring drive-related I/Os Onboard I/Os and terminal modules configuration overview Using SINAMICS I/Os by SIMOTION Drive-related I/Os assigned to SINAMICS can be used either completely or partially by SIMOTION. Examples here are the use of terminal modules (TMs) or onboard I/Os of the. To allow the I/Os to be used by SIMOTION, the input and output data must be transferred using message frames. This message frame configuration is used to represent the I/Os in the logical address space of SIMOTION and so can be used by a SIMOTION application. The BICO interconnections on the drive specify which I/Os are represented on the message frame. These BICO interconnections can be: Freely defined (free message frame configuration; message frame extension). Permanently defined (standard message frames, e.g. message frame 39x; axis message frames)...) Configuration dependent (TM15/TM17 High Feature). The access to the message frame for SIMOTION is made using I/O variables or input/output addresses. Depending how the I/Os are to be used, various configuration possibilities are appropriate: Commissioning Manual, 05/

96 Commissioning (software) 4.9 Configuring drive-related I/Os Table 4-2 Use of I/Os by SIMOTION, overview Configuration Description Applications Supported I/Os (drive objects) Use of message frame 39x Free message frame configuration with P915/P916 (TM15/TM17 High Feature special case) Free message frame configuration by means of BICO Expanding a message frame The 39x message frames can be used by SIMOTION to access the onboard I/Os. For the TM15/TM17 High Feature, when the module is created, an automatic interconnection to a "free message frame with P915/P916" is made. This means TMs are available exclusively for SIMOTION. Dedicated message frame for the data transmission are assigned to the associated drive objects. The "free message frame configuration using BICO", message frame 999, is used for the data transmission here. For the data transmission of the I/O data, existing message frames are extended with the process status data (PSD). These additional PSDs must then be interconnected using BICO. This is the preferred solution in cases where, for example, all SIMOTION I/Os are to be used. Use of: Onboard DI/DO High-speed outputs for output cams Global probes Use of TM15 and TM17 High Feature for: High-speed DI/DO Outputs of output cam Probe inputs Preferred solution when I/Os are to be divided between SIMOTION and SINAMICS and a module view is preferred. The message frame, for example, is created on a drive object (for example, on a TM or a Control Unit). This is the preferred solution in cases where I/Os are to be divided between SIMOTION and SINAMICS and, for example, an axis view is preferable. (Drive-related I/Os are appended to each axis message frame.) Onboard I/Os on the Onboard I/Os on CU310 (no highspeed outputs for output cams) TM15 TM17 High Feature Onboard I/Os on the Onboard I/Os on the CU310 TM15 DI/DO TM31 TM41 Onboard I/Os on the Onboard I/Os on the CU310 TM15 DI/DO TM31 TM41 Note The module hardware for the 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". Further information about the TM15 and TM17 High Feature is contained in the TM15 and TM17 High Feature Commissioning Manual. 96 Commissioning Manual, 05/2009

97 Commissioning (software) 4.9 Configuring drive-related I/Os Note The "free message frame configuration using BICO" and the "message frame extension" allow you to use inputs/outputs channel-granular by SIMOTION or SINAMICS. For message frame 39x, however, all onboard terminals are interconnected automatically to message frame 39x using BICO interconnections and so available only for SIMOTION. The following is true: All onboard I/Os configured as a digital output for the drive are available for SIMOTION only, i.e. they can no longer be used by SINAMICS. Digital inputs can be used by SIMOTION and SINAMICS Use of message frame 39x The following section describes the configuration of the onboard I/Os of a SIMOTION. The configuration of the onboard I/Os of a CU310 connected to a SIMOTION controller is performed similarly. With the exception of the "high-speed output cams / DOs", the same functionality is available for a CU310 as the. Functionality of the 390, 391 and 392 message frames The onboard I/Os of the assigned to SINAMICS can be used by SIMOTION with the 39x message frames. This functionality is available as of SIMOTION V4.1, SP1. If a message frame 39x is set, however, all the onboard I/Os are interconnected automatically to this message frame 39x using BICO interconnections and so available for SIMOTION. All onboard I/Os of a Control Unit that are parameterized as a digital output are available for SIMOTION only. Digital inputs can be used by both SIMOTION and SINAMICS. In addition to the use of the onboard I/Os, the 39x message frame permits the use of: High-speed outputs for output cams and high-speed digital outputs (DO) "Global" measuring inputs The control and status word of the control unit (CU_STW, CU_ZSW) Depending on the selected 39x message frame, various functionalities can be used with SIMOTION D. Commissioning Manual, 05/

98 Commissioning (software) 4.9 Configuring drive-related I/Os Table 4-3 Functionality of the 390, 391 and 392 message frames, overview Message frame Functionality available on the DI/DO of the 390 CU_STW, CU_ZSW I/O access to the DIs and DOs Maximum of four high-speed output cams / DOs 391 CU_STW, CU_ZSW I/O access to the DIs and DOs Maximum of four high-speed output cams / DOs Maximum of two inputs for measuring inputs (global measuring inputs) 392 CU_STW, CU_ZSW I/O access to the DIs and DOs Maximum of four high-speed output cams / DOs Maximum of three inputs for measuring inputs (global measuring inputs) Because the same terminals are used, the maximum "high-speed output cams / DOs" quantity framework reduces by the number of used inputs for measuring inputs. The configuration of local measuring inputs does not require the configuration of message frame 39x. Message frame 39x configuration The following requirements must be satisfied: A SCOUT project has been created The has been created A SINAMICS Integrated drive has been configured Proceed as follows: 1. In the Project Navigator, double-click the "Configuration" entry under "SINAMICS Integrated". In the view, the "PROFIdrive message frame" tab is displayed in the "SINAMICS Integrated - Configuration" dialog. 2. Select the message frame type (SIEMENS message frame 390, 391 or 392) for the control unit. 3. Click the "Transfer to HW Config" button to transfer the message frame data to hardware configuration. A message frame 39x is configured for the control unit. The address area of the message frame is displayed in "SINAMICS_Integrated Configuration" dialog. The 39x message frame configuration automatically makes the BICO interconnections for the DI and DI/DO which are then available for SIMOTION. 98 Commissioning Manual, 05/2009

99 Commissioning (software) 4.9 Configuring drive-related I/Os Figure 4-25 Message frame 39x configuration Use of the onboard I/O by SIMOTION Message frame 390 transfers the control and status word of the Control Unit in PZD1 and the status of the onboard inputs/outputs in PZD2. For the 391 and 392 message frames, additional control and status information for the global measuring inputs is transferred. The content of these PSD3 to PSD15 is used exclusively by the measuring input technology object. Table 4-4 assignment of the addresses: Control/status word and onboard I/Os PSD Logical hardware address and bit number: Input Output PSD1 Start address message frame 39x + 0 CU_ZSW CU_STW PSD2 Start address message frame 39x + 2, bit 0 Start address message frame 39x + 2, bit 1 Start address message frame 39x + 2, bit 2 Start address message frame 39x + 2, bit 3 DI 0 DI 1 DI 2 DI 3 Start address message frame 39x + 3, bit 0 Start address message frame 39x + 3, bit 1 Start address message frame 39x + 3, bit 2 Start address message frame 39x + 3, bit 3 DI 8 DI 9 DI 10 DI 11 PSD3 Start address message frame 39x + 4 Used internal for global measuring inputs (only for message frame 391, 392) PSD4-7 Start address message frame 39x + +6 Used internal for global measuring inputs 1 to 2 (only for message frame 391, 392) PSD8-15 Start address message frame 39x Used internal for global measuring input 3 (only for message frame 392) DO 8 DO 9 DO 10 DO 11 To allow access by the I/Os to the individual PSDs, I/O variables must be created in SIMOTION. The input and output addresses displayed on the "PROFIdrive message frame" tab in the "SINAMICS Integrated - Configuration" dialog are required for this purpose. The following figure shows an example of I/Os created in SCOUT: In this example, the start address of the 390 message frame for the input and output data is each 276. Commissioning Manual, 05/

100 Commissioning (software) 4.9 Configuring drive-related I/Os Figure 4-26 Example: Access to message frame 390 using I/O variables. Configuring DI/DO as input or output When a DI/DO is to be used as digital input or digital output, interconnection screen forms can be used for configuring. Proceed as follows: 1. Double-click the "Inputs/outputs" entry below the SINAMICS_Integrated > Control Unit in the Project Navigator. 2. Click the "Bidirectional digital inputs/outputs" tab. 3. In this tab, configure the required inputs or outputs. Figure 4-27 Configuring DI/DOs as input or output The configuration can also be set channel-granular on the p728 parameter using the expert list of the control unit. Note When the 39x message frames are used, a HW Config must always be performed after changes have been made to onboard I/O-relevant parameters. "Download to the target system" must then be used to download the changed configuration data into the target device. The matching is always made only for the associated selected control unit and not project-global. 100 Commissioning Manual, 05/2009

101 Commissioning (software) 4.9 Configuring drive-related I/Os Free message frame configuring with P915/P916 (only TM15/TM17 High Feature) The TM15 and TM17 High Feature Terminal Modules are connected to the Control Unit via the DRIVE-CLiQ interface. This assigns the terminal modules to the SINAMICS. When a TM15 or TM17 High Feature is added to SIMOTION SCOUT, an automatic interconnection to a "free message frame with P915/P916" is made. There are no other interconnection options for the TM15 (does not apply to the TM15 DI/DO) or TM17 High Feature. The structure and the length of the message frame depends on the configured properties of the inputs and outputs. The I/O channels can be parameterized as digital input, digital output, input for measuring input or output for output cam. The automatic interconnection of the message frame means the functionality of the modules can only be used by SIMOTION and is controlled from the SIMOTION user program using input/output addresses or I/O variables. A drive-side configuring using BICO / DCC SINAMICS is not possible. Additional references Additional information about this topic is available in the following documents: To configure TM15 and TM17 High Feature, refer to the SIMOTION TM15 and TM17 High Feature Commissioning Manual. To configure output cams and measuring inputs, refer to the SIMOTION Motion Control Output Cams and Measuring Inputs Function Manual. For I/O processing with the TM15 and TM17 High Feature (timing, classification in the task system), refer to the SIMOTION SCOUT Basic Functions Function Manual. Commissioning Manual, 05/

102 Commissioning (software) 4.9 Configuring drive-related I/Os Configuring free message frames by means of BICO Overview When "configuring free message frames by means of BICO", dedicated message frames for data transfer are assigned to the associated drive objects (e.g. Terminal Modules). Message frame type: Configuring free message frames by means of BICO (message frame 999) In order to enable SIMOTION to access the SINAMICS drive signals, e.g. I/Os, they must be interconnected to the message frame on SINAMICS using BICO. The "free message frame configuring using" is a preferred solution when I/Os are to be divided channel-granular between SIMOTION and SINAMICS and a module view is preferred. Table 4-5 Drive object: Maximum number of PSDs Drive object Maximum number of PZD items for configuring PROFIdrive message frames Input data (from the SIMOTION D viewpoint) TM15 DI/DO 5 5 TM TM Control Unit (CU) 15 5 Output data (from the SIMOTION D viewpoint) Free message frame configuring using the TM31 as example The example describes the interconnection of a signal to the TM31 connected to a SIMOTION. Steps in configuring user-specific message frames using BICO: Configuring a user-specific message frame Interconnecting the message frame for TM31 Create I/O variables in SIMOTION SCOUT Prerequisite You have already created a project and configured a drive. 102 Commissioning Manual, 05/2009

103 Commissioning (software) 4.9 Configuring drive-related I/Os Configuring a user-specific message frame 1. Double-click "Insert I/O component" under "SINAMICS_Integrated" in the project navigator, and then select the "TM31" Terminal Module from the "Drive objects type" field in the dialog that appears. 2. Enter a name for the module to be inserted and confirm your entry with OK. 3. Double-click "Configuration" under "SINAMICS_Integrated" in the project navigator to open the "PROFIdrive Message Frame" screen form. "Free message frame configuration with BICO" (message frame 999) is set for the inserted TM31. Insert the number of PSDs (Process Status Data) for I/O data. You must adhere to the maximum possible number of PZD items for the various drive objects (see previous table). A TM31, for example, supports a maximum of 5 PZD items in both the send and receive direction. 4. For the purposes of this example, enter the value 3 in the "Length" column under "Input data" or "Output data". Figure 4-28 Inserting a specific number of PSDs for the I/O data. 5. Click "Transfer to HW Config" in order to transfer the data to HW Config and to read the address space of the I/O data. Note Before the matching, all drive objects without input/output addresses (" ") must be moved behind the objects with valid input/output addresses or those still to be matched ("???..???"). The icons in the status column show the following information: The message frame is configured differently in HW Config. You must match with HW Config. You are using a predefined standard message frame or free BICO interconnection. You are using an altered standard message frame, which you have extended to include additional data. You are using a message frame for which one of the two message frame lengths is too long. The drive object cannot process this entry. Commissioning Manual, 05/

104 Commissioning (software) 4.9 Configuring drive-related I/Os Figure 4-29 Reading the I/O address space You can now transfer data from the TM31 to SIMOTION (PROFIdrive send direction) or receive data from there (PROFIdrive receive direction). Interconnecting the message frame for TM31 The next section describes how you can transfer signals from the TM31 to SIMOTION (PROFIBUS send direction). 1. Double-click the "PROFIBUS" entry in the "Communication" dialog of the TM31 you created. The corresponding dialog box opens. 2. Switch to the "PROFIBUS send direction" tab. 104 Commissioning Manual, 05/2009

105 Commissioning (software) 4.9 Configuring drive-related I/Os 3. Select the source for process data word 1 (PZD1), indicated by a blue icon. Under "TM31", select "More interconnections..." followed by "r CO/BO: TM31 digital inputs status". Figure 4-30 Selecting the PSD 4. Now interconnect analog inputs AI 0 and AI 1 in the same way (r4055[0] and r4055[1], current value in percent; 100% = 4000 hex). Figure 4-31 Interconnecting the TM31 digital and analog inputs How to transfer a signal from SIMOTION to TM31 (PROFIBUS receive direction): Commissioning Manual, 05/

106 Commissioning (software) 4.9 Configuring drive-related I/Os 1. Double-click the "PROFIBUS" entry in the "Communication" dialog of the TM31 you created. The corresponding dialog box opens. 2. Switch to the "PROFIBUS receive direction" tab. 3. For PZD1, click the icon for bit-by-by representation and interconnect the individual bits with p4038 (DO 8) to p4041 (DO 11), as well as p4030 (DO 0) and p4031 (DO 1). Interconnect analog outputs AO 0 and AO 1 with PZD2 and PZD3 (p4071[0] and p4071[1]). Figure 4-32 Interconnecting the TM31 digital and analog outputs Creating an I/O variable in SIMOTION In order to access the TM31 signals, you must create I/O variables in SIMOTION. For this purpose, you require the input or output addresses for the TM31 message frame in the "PROFIdrive Message Frame" screen form. This allows you to assign a complete word, a byte, or a single bit to the variables. 1. In the project navigator, double-click "I/O" at the SIMOTION entry you created. The symbol browser opens 2. Enter a name for the I/O variable. 3. Enter an I/O address, e.g. "PI277.0" - This enables you to access PZD1, bit 0 of the configured message frame. "PI276.0" - This enables you to access PZD1, bit 8 of the configured message frame. SIMOTION can now access the signal. The PROFIdrive profile specifies that the process status data (PSD) is defined as a 16-bit value. When determining the I/O address, it must be noted that the low-order byte of the SIMOTION I/O variable is assigned to the high-order PZD bits of the message frame, and vice versa: Table 4-6 Byte representation/pzd representation assignment I/O address Byte 276 Byte 277 Bytes represented in bit format PSD in bit representation In the example, the I/Os have the following addresses: 106 Commissioning Manual, 05/2009

107 Commissioning (software) 4.9 Configuring drive-related I/Os DI 0 to 7 Addresses PI to PI DI/DO 8 to 11 Addresses PI to PI (if DI/DO has been parameterized as DI) AI 0 Address PIW 278 AI 1 Address PIW 280 DI/DO 8 to 11 Addresses PQ to PQ (if DI/DO has been parameterized as DO) AO 0 Address PQW 278 AO 1 Address PQW Expanding a message frame Extending a message frame involves extending existing standard message frames (e.g. axis message frames) to include additional process data (PZD). These additional PSDs are then interconnected using BICO (e.g. to an actual speed value or to the status of a digital input). A message frame extension is then the preferred variant when I/Os are to be distributed between SIMOTION and SINAMICS and, for example, an axis view is preferred (driverelated I/O should be appended to each axis message frame). Proceed as follows: 1. Insert a drive using the Drive Wizard and make a selection for process data exchange, such as "Standard message frame 103". 2. Double-click "Configuration" below "SINAMICS_Integrated" in the project navigator in order to open the "PROFIdrive message frame" tab. The tab contains the default length of I/O data for the drive you inserted. As the addresses of I/O data have not yet been transferred to HW Config the default entry "???" is set. 3. Select the row of the object of which you want to expand the message frame. Figure 4-33 PROFIdrive message frame Commissioning Manual, 05/

108 Commissioning (software) 4.9 Configuring drive-related I/Os 4. Click "Add line" and select the "Message frame expansion" option in the menu shown. A new line which contains the message frame expansion is inserted below the current line. 5. Enter the "length" for the number of PSDs by which the message frame is to be extended in the Input data and Output data columns. Note Before the matching, all drive objects without input/output addresses (" ") must be moved behind the objects with valid input/output addresses or those still to be matched ("???..???"). The icons in the status column represent the following information: The message frame is configured differently in HW Config. You must perform alignment with HW Config. You are using a predefined standard message frame or free BICO interconnection. You are using an altered standard message frame, which you have extended to include additional data. You are using a message frame for which one of the two message frame lengths is too long. The drive object cannot process this entry. 6. Click the "Transfer to HW Config" button to transfer the changes to HW Config. A red check mark will be placed in the line to indicate that a standard message frame to which changes have been made is being used. The I/O address data is entered after its transfer to HW Config. 7. Change to the configured drive and double-click the "PROFIBUS" entry in "Communication". 108 Commissioning Manual, 05/2009

109 Commissioning (software) 4.9 Configuring drive-related I/Os 8. Deactivate the "Hide inactive interconnections" to display all the PZD items for the message frame. The send and receive data (at least 16) are displayed. The first PSDs are assigned the standard message frame by default and cannot be changed. 9. Interconnect the PSDs (at the end of the PSD list) that you have added with the required signals by means of BICO. Figure 4-34 Example: Interconnection of the onboard DI in the PROFIBUS send direction Note A warning message is not output if you interconnect more PSDs than were set in the additional PSDs. Note that a SERVO drive object supports a maximum of 16 PSD setpoints and 19 PSD actual values. Each VECTOR drive object supports a maximum of 32 PSD setpoints. Commissioning Manual, 05/

110 Commissioning (software) 4.9 Configuring drive-related I/Os Using high-speed outputs for output cams on Using high-speed outputs for output cams / DOs with Output cams are defined as being the position-dependent output of switching signals. The TO output cam and TO cam track technology objects control the output of the output cam for SIMOTION. The onboard digital outputs of the SIMOTION can be used as an output for the output cam or a high-speed output with write access to the user program. In order to be able to use the high-speed outputs, one of the 39x message frames must be created. Note If I/O data is transferred using bus message frames, the update of the I/O data is subject to the set bus cycle. This means an I/O using a 39x message frame can change its status just once in each bus cycle of the PROFIBUS Integrated. In the case of SIMOTION onboard outputs, the outputs are controlled using direct write accesses to the hardware (i.e. bypassing the message frame). This means: Write accesses to digital outputs act with a particularly short delay time because the write access is independent of the bus cycle. A more accurate output of the cam output is possible For fast write accesses from the user program, the resulting delay time has the following form: User program delay time -> terminal register: Maximum 75 μs Load-dependent output delay time of the hardware for : L -> H: max. 400 μs H -> L: max. 100 μs High-speed outputs of output cams If you use the output as high-speed output of a cam output, for the configuration of the TO output cams / TO output cam track, enter the logical hardware address and the bit number of the used output in the configuration screen form of the TO. For additional information, see the SIMOTION Motion Control Output Cams and Measuring Outputs Function Manual. High-speed digital outputs If you use the output as high-speed digital output, create an I/O variable in SIMOTION SCOUT. The same addresses should be used for the high-speed digital outputs as those normally used for the digital outputs. Table 4-7 Logical hardware address and the bit number (high-speed outputs for cam outputs / DOs) Logical hardware address and bit number Output on the Start address message frame 39x +3, bit 0 DO 8 Start address message frame 39x +3, bit 1 DO 9 Start address message frame 39x +3, bit 2 DO 10 Start address message frame 39x +3, bit 3 DO Commissioning Manual, 05/2009

111 Commissioning (software) 4.9 Configuring drive-related I/Os Additional references For information on how to configure message frame 39x and how to parameterize a DI/DO as a DO, refer to the section titled Use of message frame 39x (Page 97) Using probe inputs on Configuration of probe inputs Measuring inputs are used for fast, accurate measurement of actual positions. This is achieved with the support of hardware (for example, the measuring input on the assigned drive unit). Digital inputs for standard peripherals, e.g. the SIMATIC ET 200 distributed I/O system, cannot generally be used as probe inputs. For SIMOTION, the TO probe input technology object controls the probe input functionality. SIMOTION differentiates between two classes of the probe inputs; these classes have different properties that are configured differently. 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 timestamp to the measurement result for more precise determination of the axis positions. The term "central probe" is also used within the context of drives. Table 4-8 Comparison of local and global measuring inputs on the Local measuring input Global measuring input Hardware supported, D4x5, CX32, CU310, CU320 TM15, TM17 High Feature V4.1 SP1 and higher:, D4x5 V4.1 SP2 and higher: CX32, CU310, CU320 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 timestamp 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 Measuring Input TO 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 Measuring Input TO using the measuring input number. The assignment of inputs is not fixed depending on the hardware and is performed during the configuration of the Measuring Input TO using the hardware address. Commissioning Manual, 05/

112 Commissioning (software) 4.9 Configuring drive-related I/Os Measuring Input technology object setting Single measurement (Measurement jobs must be issued individually for each measurement. Several interpolation cycle clocks lie between two measurements.) Measuring Input technology object setting Cyclical measurement (The measurement is activated just once and runs cyclically until deactivated.) Use of multiple Measuring Input TOs on one axis/encoder, whereby these can be active concurrently. Local measuring input Yes No No Listening Measuring Input TO No Yes Measuring on virtual axes No Yes Measuring on axes attached to a different drive unit No Yes Global measuring input Yes Yes D4x5, CX32, CU310, CU320: The minimum interval between two measurements is 3 servo cycles (max. 2 edges per measurement). TM17 High Feature: Minimum interval between two measurements is 1 servo cycle (max. 2 edges per measurement). TM15: Cyclical measurement not available Yes A maximum of three probe inputs can be configured onboard on the. Table 4-9 Probes - Overview of quantity structures and functionality Maximum number of probe inputs Can be configured as a local probe Can be configured as a global probe Maximum available quantity structure CU310 D4x5 CX32 CU320 TM15 TM17 High Feature x x x x - - x x x x x x 112 Commissioning Manual, 05/2009

113 Commissioning (software) 4.9 Configuring drive-related I/Os Configuring of local measuring inputs on the Local measuring inputs are always permanently assigned to an axis (drive). They are configured separately for each drive. The drive and the probe input must always be located on the same control unit. The measuring 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. Table 4-10 Local probes, required settings in the expert list (1) Parameters in the expert list of the CU Parameterization as Any DI/DO used as a measuring p728[8] (DI/DO 8) Not applicable 1) input must be parameterized as p728[9] (DI/DO 9) Input an input in the Control Unit expert list. p728[10] (DI/DO 10) Input p728[11] (DI/DO 11) Input 1) Not applicable, as this I/O cannot be used as a probe input. Table 4-11 Local probes, required settings in the expert list (2) Specification of the input terminal of the measuring input in the expert list of the drive Parameters in the expert list of the drive Parameterization as p488[0] DI/DO 9 or (measuring input 1 input terminal, encoder 1) DI/DO 10 or p488[1] DI/DO 11 (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) p489[2] (measuring input 2 input terminal, encoder 3) 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 Measuring Input TOs can be configured per Axis TO or External Encoder TO. Only one Measuring Input TO can be active on an Axis TO or External Encoder TO. Table 4-12 Local measuring inputs, configuration of the Measuring Input TO Axis measuring system no. Local measuring Measuring input number 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. Activate the checkbox when a local measuring input is used. Enter here which measuring input is used (namely, 1 or 2). Input 1 is the default setting. Detailed information is contained in the SIMOTION Motion Control Output Cams and Measuring Outputs Function Manual. Commissioning Manual, 05/

114 Commissioning (software) 4.9 Configuring drive-related I/Os Configuring of global measuring inputs on the Global measuring inputs can be freely assigned to the axes (drives) and add an internal timestamp to the measurement result for more precise determination of the axis positions. The drive and the probe input do not need to be located on the same control unit. The measuring results are not transferred using the axis message frame, but using the 391/392 axis message frame. Table 4-13 Global probes, required settings in the expert list (1) Parameters in the expert list of the CU Parameterization as Any DI/DO used as a p728[8] (DI/DO 8) Not applicable 1) measuring input must p728[9] (DI/DO 9) Input be parameterized as an input in the Control p728[10] (DI/DO 10) Input Unit expert list. p728[11] (DI/DO 11) Input 1) Not applicable, as this I/O cannot be used as a probe input. Table 4-14 Global probes, required settings in the expert list (2) Specification of the input terminal of the measuring input in the expert list of the control unit Parameters in the expert list of the CU p680[0] (probe input terminal) p680[1] (probe input terminal) p680[2] (probe input terminal) Parameterization as DI/DO 9, DI/DO 10, or DIDO 11 In addition to the settings of the parameters, message frame 391 (max. two measuring inputs) or message frame 392 (max. three measuring inputs) must be set for the control unit. The p680 parameter is used to define a terminal as global probe inputs. Message frame 391 can be used to assign the p680[0..1] parameter; message frame 392 can be used to assign the p680[0..2] parameter. The parameter used to set the required terminal is not relevant. The assignment of the measuring input to an axis is made using the logical hardware address and the bit number of the digital input to be used as measuring input (see also Section Use of message frame 39x (Page 97)). Note The Control Unit parameters p490, p684, and r685 to r688 are of no relevance to SIMOTION. Note When the 39x message frames are used, a HW Config must always be performed after changes have been made to onboard I/O-relevant parameters. "Download to the target system" must then be used to download the changed configuration data into the target device. 114 Commissioning Manual, 05/2009

115 Commissioning (software) 4.9 Configuring drive-related I/Os Table 4-15 Global measuring inputs, configuration of the Measuring Input TO Axis measuring system no. Global measuring Logical hardware address and bit number: 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. Activate the checkbox when a global measuring input is used. Enter here the logical HW address and the bit number of the used input. Start address message frame 39x + 3, bit 1 for input DI/DO 9 Start address message frame 39x + 3, bit 2 for input DI/DO 10 Start address message frame 39x + 3, bit 3 for input DI/DO 11 Detailed information is contained in the SIMOTION Motion Control Output Cams and Measuring Outputs Function Manual Outputs of cam outputs and probe inputs on TM15/TM17 High Feature Quantity framework for TM15/TM17 High Feature The TM15/TM17 High Feature Terminal Modules can be used to extend the number of outputs for cam outputs and probe inputs that can be installed. TM15, maximum 24 outputs for cam outputs / probe inputs TM17 High Feature, maximum 16 outputs for cam outputs / probe inputs Additional references Detailed information for the configuration is contained in the following documents SIMOTION Output Cams and Measuring Inputs Function Manual TM15/TM17 High Feature Terminal Modules Commissioning Manual Programming examples/additional information Additional information and programming examples for configuring drive-related I/Os can be found At Internet address ( In SIMOTION Utilities & Applications. SIMOTION Utilities & Applications is provided as part of the SIMOTION SCOUT scope of delivery. Commissioning Manual, 05/

116 Commissioning (software) 4.10 Creating and programming TM Creating and programming TM 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. Configuring the TM41 involves the following steps: Configuring TM41 at SINAMICS Integrated Configuring TM41 using the Axis Wizard. Note The digital I/Os and the analog input can be interconnected using BICO configuration in the same way as a TM31. The TM41 encoder interface (incremental encoder representation) can Be interconnected with a Control Unit encoder signal (from sin/cos incremental encoders, for example), using parameterization. For detailed information, consult the SINAMICS manuals. From the SIMOTION viewpoint, can be accessed as axis. This allows you to make the axis position (a master value) available to a second controller as an encoder signal, for example. Detailed information is contained in the SIMOTION D4x5 Commissioning and Hardware Installation Manual. The second application case can only be used with SIMOTION with restrictions, because the TM41 is configured as a real axis. Because SIMOTION supports just one real axis, no additional real axis can be configured Configuring TM41 at SINAMICS Integrated TM41 can be configured after you completed the configuration of SINAMICS Integrated. Proceed as follows: 1. Double-click "Insert InputIOutput Ccomponent" at "Input/output component" in the Project Navigator. 2. Select the 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. 116 Commissioning Manual, 05/2009

117 Commissioning (software) 4.11 Creating a DMC Creating a DMC DMC20 hub properties DRIVE-CLiQ hub properties The DMC20 DRIVE-CLiQ hub can be used to extend the number of DRIVE-CLiQ interfaces and to configure a star topology. You must increase the number of DRIVE-CLiQ interfaces if connecting the following additional components to the SIMOTION : Direct measuring systems Terminal modules Reduction of the network hierarchy levels A star topology has the following advantages: The components can operate as end node of your segment. Line communication is not affected. Application examples Encoder expansion and hot-plugging are typical applications implemented by means of a DRIVE-CLiQ hub. An encoder expansion involves integration of direct measuring systems. These are installed in the control cabinet directly at the machine. Several encoders can be connected to the same hub. Note: The SIMOTION has precisely one DRIVE-CLiQ interface. You can use the DMC20 to evaluate the motor encoder and an additional encoder by means of SMx. Hot plugging is the option for changing motor components while in operation. These components are connected to a star topology using a DRIVE-CLiQ hub. This setup allows their deactivation without impairing downstream components. Additional references Information pertaining to the DMC20 DRIVE-CLiQ hub is available in the SIMOTION Manual. Commissioning Manual, 05/

118 Commissioning (software) 4.12 Optimizing the drive and controller Creating a DRIVE-CLiQ hub The hub is not wired when you insert the DMC20 and is represented in the topology tree in the component storage. The hub has to be wired manually. Proceed as follows: 1. Right-click the "Topology" entry in the Project Navigator. 2. Select the "Insert new object" > "DRIVE-CLiQ Hub" command from the shortcut menu and confirm with "OK". 3. Double-click "Topology" to open the topology tree. The hub is saved to the component storage of the topology tree. 4. Drag-and-drop the hub to the required DRIVE-CLiQ interface. The components connected to the hub are displayed in the topology tree. The hub you inserted is displayed as icon at the "Topology" entry in the Project Navigator. All components connected to a hub are also displayed in the course of automatic configuration Optimizing the drive and controller Overview of automatic controller setting Overview SIMOTION SCOUT offers an automatic controller setting wizard that can be used for drive controller optimization. In the "Automatic Controller Setting" screen form, you can automatically set the speed controller and the DSC (dynamic servo control) position controller for SINAMICS drive units. The necessary steps for this calculation can be controlled using 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 "Target System" > "Automatic Controller Setting" menu command. For a detailed description of the parameters that can be set, refer to the SIMOTION SCOUT online help. Prerequisites You have configured a SINAMICS drive. The configured drive is operated in the "Servo" drive object type. Control takes place with the motor encoder. There is an online connection to the relevant drive unit. 118 Commissioning Manual, 05/2009

119 Commissioning (software) 4.12 Optimizing the drive and controller 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 canceled. The drive enable is locked. 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 the sections titled Measuring functions, trace, and function generator (Page 122) and Manual speed controller optimization (Page 124)) Automatic speed controller setting Features 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 reset time Tn of the speed controller. The speed setpoint filter and the reference model are not adjusted. Procedure To perform 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 "Controller Selection". 4. Click "Assume control priority!" to assume control priority. 5. Click 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. Commissioning Manual, 05/

120 Commissioning (software) 4.12 Optimizing the drive and controller 8. Click the "Give up control priority!" button to give up the control priority of the programming device/pc. 9. Save the online parameters. You can now transfer the parameters that you have automatically set to the project. Backing up parameters Proceed as follows to back up the parameters: 1. In the project navigator, select the SINAMICS device with the drive for which you want to perform automatic setting. 2. Select "Copy RAM to ROM" from the context menu. 3. Select "Load to PG" from the context menu. If necessary, the automatic controller settings can be verified with the measuring functions Automatic position controller setting Introduction In the "Automatic Controller Setting" screen form, you can select the drive unit and the drive for which you want to perform automatic DSC position controller setting. The steps required for this calculation can be performed via 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. Prerequisites In addition to the general prerequisites for automatic controller setting, the following boundary conditions apply for setting the position controller: DSC is required for position controller setting. The speed controller must have already been configured (e.g. using automatic speed controller setting). One axis must be connected to the SINAMICS drive (servo). The actual values and manipulated variables between the controller and the drive must have been correctly standardized by the user. These values are not checked. An online connection to the SIMOTION device must be established to transfer the results of 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 (PostionTimeConstant = 1/Kv). Vibration on the load side is not taken into account for position controller setting. 120 Commissioning Manual, 05/2009

121 Commissioning (software) 4.12 Optimizing the drive and controller Procedure To perform 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. Click 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 programming device/pc. 10. Save the online parameters. You can now transfer the parameters that you have automatically set to the project. Backing up parameters Proceed as follows to back up the parameters: 1. In the project navigator, select the SIMOTION device with the axis for which you want to perform automatic setting. 2. Select "Copy Current data to RAM" from the context menu. 3. Select "Copy RAM to ROM" from the context menu. 4. Select "Load Configuration Data to PG" from the context menu. If necessary, the automatic controller settings can be verified with the measuring functions. Commissioning Manual, 05/

122 Commissioning (software) 4.12 Optimizing the drive and controller 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 knowledge of control engineering. Controller optimization Various measuring functions are available for drive controller optimization. Using simple parameterization, these measuring functions enable the influence of higher-level control loops to be selectively switched off and the dynamic response of individual drives to be analyzed. The function generator and trace recorder are used. The control loop is supplied with the function generator signal at a specific point (e.g. speed setpoint), and the signal is recorded by the trace recorder at another point (e.g. speed actual value). Figure 4-35 Optimizing a controller Depending on the form of controller optimization to be performed, it is possible to define the quality (e.g. waveform, amplitude, settling time) of the disabled signal, the measurement period for jump functions in the time range, or the bandwidth and number of averaging operations in the frequency range for the recording. The analytical and graphical evaluation can then be performed accordingly (FFT diagram, Bode diagram). The following measuring functions are available: Setpoint jump at current controller Reference frequency response at current controller Setpoint jump at speed controller 122 Commissioning Manual, 05/2009

123 Commissioning (software) 4.12 Optimizing the drive and controller Interference jump at speed controller Reference frequency response at speed controller Interference frequency response at speed controller Speed-controlled system (excitation at current setpoint filter) Additional references For additional information about drive optimization, consult the SINAMICS S120 Commissioning Manual. More detailed information on trace and measuring functions, as well as on the function generator, can be found in the SIMOTION SCOUT online help. Commissioning Manual, 05/

124 Commissioning (software) 4.12 Optimizing the drive and controller Manual speed controller optimization Prerequisite 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 enter online mode. 2. Click to call the "Measuring Functions" dialog. 3. Select the drive unit and the drive. 4. Select "Speed controller setpoint jump" as the measuring function. You can change the values in the following fields: "Settling time", "Amplitude", "Offset", "Ramp-up time", and "Measuring time". Four channels can be recorded. Depending on the measuring function, certain channels are preassigned. Figure 4-36 Speed controller measuring function 5. Download the changes to the drive by clicking (Download Parameter Assignment). 124 Commissioning Manual, 05/2009

125 Commissioning (software) 4.12 Optimizing the drive and controller Starting the measuring function 1. Click "Assume control priority!" to assume control priority. Read the notice that appears and click "Accept" to confirm. 2. Click the "Drive ON" button to enable the drive. 3. Click (Start measuring function) to start the measuring function. The axis is moved during measurement. For this reason, a safety message that allows the process to be canceled is displayed. After reading the notices, you can begin the measurement with "Accept" or cancel it with "Abort". 4. The signals recorded are represented on the "Timing Diagram" tab. Figure 4-37 Timing diagram before parameterization Commissioning Manual, 05/

126 Commissioning (software) 4.12 Optimizing the drive and controller Adjusting the P-gain You can adjust the P-gain of the controller to optimize the transient response. 1. Under the corresponding drive (Servo_1, for example) in the project navigator, use the menu command "Open-Loop/Closed-Loop Control" > "Speed Controller" to display the "Speed Controller with Encoder" dialog window. 2. Enter an appropriate value in the "P-gain" field and the "Reset time" field. CAUTION The values entered take immediate effect. Figure 4-38 Entering the P-gain 126 Commissioning Manual, 05/2009

127 Commissioning (software) 4.12 Optimizing the drive and controller 3. For verification purposes, perform the measurement again. 4. With the modified parameters, the controller demonstrates a much better transient response. If necessary, you can continue changing the value until the transient response has reached its optimum level. Figure 4-39 Measurement with modified P-gain Commissioning Manual, 05/

128 Commissioning (software) 4.13 Downloading and saving user data 4.13 Downloading and saving user data Overview It is advisable to backup all user data (programs, configuration data, parameters) to the CompactFlash Card after having completed commissioning of SIMOTION. Downloading user data Use the "Target system > Download > Download to the target system" command to transfer the following data from the SIMOTION SCOUT Engineering System (ES) to the "non-volatile data" area of SIMOTION : Configuration data Programs Parameterization Technology packages The hardware configuration of SIMOTION and the retain variables are also saved to the "nonvolatile data" area. Note Using the menu: "Target system > Download > Project to target system" downloads all the project data to the target system. "Target system > Download > Download to target device" only downloads the data for the selected device/drive element to the target device. All contents of the "volatile data" area are lost after you shut down SIMOTION! Additional references Additional information on the SIMOTION SCOUT engineering system can be found in the SIMOTION SCOUT Configuration Manual. Saving user data The "Copy RAM to ROM" function is used in SIMOTION SCOUT to save the following data from RAM to the CompactFlash card: Technology packages and user data (units, configuration data, parameters, task configuration) of the "volatile data" area Actual values are copied to the "volatile data" area, depending on the settings in SIMOTION SCOUT. Note The "Copy RAM to ROM" command cannot be used to save the actual value of retain variables to the CompactFlash Card. 128 Commissioning Manual, 05/2009

129 Commissioning (software) 4.14 Deleting data You have the following options for backing up the current values of retain variables to the CompactFlash Card: In the user program Use the "_savepersistentmemorydata" system function for this purpose. Using a switch position (SIMOTION service selector switches) or IT DIAG For information on this, refer to the section titled Diagnostic data and non-volatile data (Page 172). 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 were changed during operation and only stored in the runtime system. Execute the "Copy RAM to ROM" function separately for SINAMICS Integrated. This requires that the drive element has been selected in the Project Navigator. See also Properties of the user memories (Page 32) 4.14 Deleting data Overview of data deletion You can define the scope of data to be deleted from SIMOTION memory described in the "user memory concept". That is, you can choose to delete all data or only specific parts. You have the following options of deleting data from SIMOTION : For information on performing a SIMOTION memory reset, refer to the section titled Resetting the memory of SIMOTION (Page 130). For information on deleting user data on a CompactFlash Card, refer to the section titled Deleting user data from the CompactFlash Card (Page 133). For information on restoring the SINAMICS Integrated to its factory settings, refer to the section titled Restoring the default settings of SINAMICS Integrated (Page 134). For information on setting the SIMOTION to its factory settings, refer to the section titled Restoring the default settings of SIMOTION (Page 134). Commissioning Manual, 05/

130 Commissioning (software) 4.14 Deleting data Resetting the memory of SIMOTION Introduction A memory reset deletes all data from RAM on the SIMOTION and non-volatile data in the FRAM, with the exception of the communication configuration (baud rates, network addresses, etc.). Data on the CompactFlash Card is retained if you reset the memory. Reset the memory on SIMOTION if You want to undo changes made to user data (programs, configuration data, parameter assignments) which you have not backed up by means of the "Copy RAM to ROM" command. The RUN/STOP LED is flashing (slowly flashing yellow) to indicate that the SIMOTION is requesting a memory reset. Non-volatile data does not match the project on the CF card and an error is generated (diagnostics buffer entry). You can reset memory either in offline mode using the DIL switch of SIMOTION, or in online mode using SIMOTION SCOUT. Data deleted by memory reset The following data is deleted during a memory reset: User data (units, configuration data, parameters, task configuration) Technology packages 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 As a memory reset deletes all absolute encoder data the encoder must be re-adjusted after memory reset. 130 Commissioning Manual, 05/2009

131 Commissioning (software) 4.14 Deleting data Data retained during memory reset The following data is retained during memory reset: TCP/IP and DP parameters Diagnostics buffer Data that was saved with the _savepersistentmemorydata, _saveunitdataset, _exportunitdataset and RAMtoROM commands and with the "Copy RAM to ROM" function. The data contents of a backup file generated by executing _savepersistentmemorydata (PMEMORY.XML/PMEMORY.BAK) is written back to non-volatile data after memory reset. Users can therefore force the restoration of non-volatile data by means of memory reset. Licenses The technology packages and user data (configuration data, programs, parameter assignments) you previously backed up to a CompactFlash Card by means of the "Copy RAM to ROM" command are transferred to the "non-volatile data" area of the SIMOTION 410 during the next startup. This operation transfers any configuration data found on the CompactFlash Card to the SIMOTION device after memory reset. Memory reset by means of SIMOTION SCOUT You can only reset memory using SIMOTION SCOUT if SIMOTION is operating in online mode. 1. Select SIMOTION from the Project Navigator of SIMOTION SCOUT. 2. Select the "Target device > Control system mode" command from the shortcut menu in order to open the ": System Mode" dialog box. 3. Select the STOP mode. 4. Next, select the MRES mode to reset the memory. Commissioning Manual, 05/

132 Commissioning (software) 4.14 Deleting data Memory reset using the mode selector switch The mode selector switch function is implemented in SIMOTION by means of a DIL switch (DIL = Dual-In-Line). Use this DIL switch (switch S1 - S3) to set the binary code for the mode of operation. Information pertaining to to the switch positions and corresponding modes of operation is available in the SIMOTION Manual. You can only reset memory using the mode selector switch if SIMOTION is operating in offline mode. How to reset the memory: 1. Select the MRES operating mode by Setting mode selector switches S1 to S3 to OFF AND Using the service selector switch to ensure that no service functions are selected (S4 to S7 = OFF). The RUN/STOP LED will begin flashing soon after this (slowly flashing yellow). Figure 4-40 Switch position MRES 2. Set switch 1 to ON (STOP mode) once the RUN/STOP LED permanently lights up yellow. 3. Within 3 seconds, set the switch back to MRES operating mode by setting switch S1 to OFF again. The memory reset is performed (the RUN/STOP LED flashes yellow quickly). 132 Commissioning Manual, 05/2009

133 Commissioning (software) 4.14 Deleting data 4. Wait until the has completed the memory reset (RUN/STOP LED permanently lights up yellow). 5. Now set the mode selector switch back to the required operating mode; for example, set switches S1, S2, and S3 to ON for RUN mode. Note Memory reset is cancelled if you do not return the DIL switch to MRES as specified within three seconds. Repeat the procedure in this case. NOTICE Please note that, during startup, the MRES setting will cause the factory settings to be restored. For details, refer to the section titled Restoring the default settings of SIMOTION (Page 134). Make sure you do not accidentally switch the power supply OFF/ON while MRES is set, as this will re-establish the factory settings instead of performing a memory reset Deleting user data from the CompactFlash Card Overview You can delete the user data using SIMOTION SCOUT. SIMOTION must be operating in online mode. This deletes the following data: User data from the "volatile data" area Non-volatile data, with the exception of IP and DP parameters User data on the CompactFlash Card (user folders), including the SINAMICS configuration data You can still go online to SIMOTION at your programming device / PC. All licenses on the CompactFlash Card are retained. Deleting user data 1. Open the project you want to edit in SIMOTION SCOUT. 2. Go online to SIMOTION. 3. Select SIMOTION in the Project Navigator, and then select the "Delete user data on card" option from the "Target system" menu. 4. Confirm the "Delete user data from card" message with "OK". The user data are deleted. SINAMICS Integrated goes into offline mode. Commissioning Manual, 05/

134 Commissioning (software) 4.14 Deleting data 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 Restoring the default settings of SIMOTION Overview SIMOTION is supplied with default parameters such as the transmission rate or PROFIBUS addresses. You can restore the default settings using the DIL switch. This deletes the following data: Non-volatile data in the SIMOTION device The backup copy of non-volatile data on the CompactFlash Card (PMEMORY.XML/PMEMORY.BAK) User data in the "volatile data" area and on the CompactFlash Card The communication configuration (IP and DP parameters) on the CompactFlash Card is set to the factory settings. All licenses on the CompactFlash Card are retained. 134 Commissioning Manual, 05/2009

135 Commissioning (software) 4.14 Deleting data Restoring the default settings using the DIL switch 1. The power supply is shut down. 2. Select the MRES operating mode by Setting mode selector switches S1 to S3 to OFF AND Using the service selector switches to ensure that no service functions are selected (S4 to S7 = OFF). (See figure below.) Figure 4-41 MRES switch position 3. Restart the power supply. The FRAM and the user data are deleted. The default settings are loaded. SIMOTION remains in STOP mode. 4. Change to the required mode by setting the DIL switch. Note The default communications parameters are now restored. You must re-configure the communication parameters of SIMOTION. Commissioning Manual, 05/

136 Commissioning (software) 4.15 System shutdown 4.15 System shutdown All axes and system components must be in safe state before you shut down the system. You can set up this safe state by providing a separate motion task, for example. You can shut down the power supply after the system has reached a standstill state. Note You must observe the safety notices for SINAMICS components, which you can find in the corresponding SINAMICS manuals Configuring Safety Integrated functions Integrated safety functions (V4.1 SP2 and higher) The integrated SINAMICS S120 safety functions, when used in conjunction with SIMOTION D, can provide highly effective application-oriented protection for personnel and machinery. The following Safety Integrated functions are currently available: (Terms in accordance with IEC ) 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) Note Currently, it is not possible to use Safety Integrated functions with devices in chassis format. For SBC, if you are using a SIMOTION in conjunction with a PM340 Power Module you also require a Safe Brake Relay, which is supported with V4.1 SP3 and higher. 136 Commissioning Manual, 05/2009

137 Commissioning (software) 4.16 Configuring Safety Integrated functions Control The Safety Integrated functions are fully 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 Via PROFIBUS with PROFIsafe ( DP only) The Safety Integrated functions are implemented on an entirely electronic basis and, therefore, offer short response times in comparison to solutions with externally implemented monitoring functions. Note Although SIMOTION does not feature any safety-related functions, 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 operating mode being monitored. Hardware required Controlling the safety functions requires at least the following hardware versions: SIMOTION DP: 6AU1410-0AA00-0AA0, product version A SIMOTION PN: 6AU1410-0AB00-0AA0, product version A 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, CU310, CU320, etc.) requires its own TM54F (assuming the relevant safety functions are to be used on the Control Unit concerned). Commissioning Manual, 05/

138 Commissioning (software) 4.16 Configuring Safety Integrated functions Safety Integrated functions with PROFIsafe 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. Examples are the SIMATIC S7-300 CPU 317F-2 DP (not pictured) or the ET 200S IM151-7 F-CPU with the PROFIBUS DP master interface module (see image). Figure 4-42 SIMOTION D, control of F functions via PROFIBUS with PROFIsafe Topologies The section below lists the topologies that may potentially be used with the SIMOTION. In each case, the description specifies whether the control of Safety Integrated functions is routed through to the drives. SIMATIC F CPU (master), connected via PROFIBUS with PROFIsafe to the SIMOTION DP (I slave) Routing to the SINAMICS Integrated drive of the DP The SIMOTION DP is the master for F slave-to-slave communication (e.g. between a SIMATIC F CPU and a CU320) Note Control for the Safety Integrated functions cannot be routed through to the SINAMICS Integrated of the in this configuration. 138 Commissioning Manual, 05/2009

139 Commissioning (software) 4.16 Configuring Safety Integrated functions Additional references Additional information on configuring Safety Integrated functions can be found in The SINAMICS S120 Safety Integrated Function Manual The TO Axis Electric / Hydraulic, External Encoder Function Manual On the Internet at Internet address ( Commissioning Manual, 05/

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141 Maintenance and service Overview Introduction It is possible to distinguish between the following scenarios when replacing and updating components: Replacing modules (spare part scenario) For information on removing and replacing the SIMOTION, refer to the section titled Removing and replacing the SIMOTION (Page 143). For information on replacing DRIVE-CLiQ components, refer to the section titled Replacing DRIVE-CLiQ components (Page 144). For information on replacing SIMOTION fans, refer to the section titled Replacing the fan (Page 147). For information on replacing a CompactFlash card, refer to the section titled Replacing the CompactFlash card (Page 149). Adapting a project (new device type/device version) The project needs to be adapted if you want to change the type (e.g. DP -> PN) or version of the SIMOTION device in your existing project. For information on replacing a SIMOTION device in HW Config, refer to the section titled Replacing the SIMOTION device in HW Config (Page 151). For information on upgrading the device version of SINAMICS components, refer to the section titled Upgrading the device version of SINAMICS components (Page 153). For information on upgrading technology packages, refer to the section titled Upgrading technology packages (Page 154). For information on upgrading a library, refer to the section titled Upgrade the libraries (Page 155). For information on backing up variables, refer to the section titled Backing up variables (Page 155). For information on upgrading a CompactFlash Card bootloader, refer to the section titled Upgrading the CompactFlash Card's bootloader (Page 156). For information on downloading a project to the target system, refer to the section titled Downloading the project to the target system (Page 156). Performing a firmware and project update For information on performing a firmware update using a CompactFlash Card, refer to the section titled Firmware update using a CompactFlash Card (Page 158). For information on performing a firmware and project update using IT DIAG, refer to the section titled Firmware and project update using IT DIAG (Page 162). For information on performing a firmware and project update using the device update tool, refer to the section titled Firmware and project update using the device update Commissioning Manual, 05/

142 Maintenance and service 5.1 Overview tool (Page 163). The upgrade data are created using the SCOUT function "Start device update tool" and then transferred to the SIMOTION using either the CompactFlash Card or an 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 updates. Please also observe the information on handling the CompactFlash card. For information on changing a CompactFlash card, refer to the section titled Replacing the CompactFlash Card (Page 165). For information on writing to a CompactFlash card, refer to the section titled Writing to a CompactFlash card (Page 166). For information on formatting a CompactFlash card, refer to the section titled Formatting the CompactFlash Card (Page 167). For information on the CompactFlash card bootloader, refer to the section titled Bootloader on the CompactFlash card (Page 167). For the recommended method of handling CompactFlash Cards, refer to the section titled Recommended method of handling CompactFlash Cards (Page 168). 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 (in isolated cases, this may refer to an upgrade or downgrade) 142 Commissioning Manual, 05/2009

143 Maintenance and service 5.2 Replacing modules (spare part scenario) 5.2 Replacing modules (spare part scenario) Removing and replacing the SIMOTION Overview You must replace the entire SIMOTION module. WARNING Always shut down the load power supply before you replace the SIMOTION module. You shut down power using the On/Off switch of the PS power supply module, for example. Note that power modules with FSB performance rating or higher still carry a residual intermediate voltage after shutdown. Wait 10 minutes before you remove any screws. Replacing defective modules How to remove the SIMOTION module: 1. Shut down the power supply. 2. Remove the CompactFlash Card from the card slot. 3. Remove the connections for the power supply. 4. Disconnect the DRIVE-CLiQ connector from the device, and the PROFIBUS DP interface (X21) or PROFINET interface (X200 and X201) connectors. 5. If necessary, disconnect the digital I/O cable connectors at interface X Disconnect the plug of any encoder connected to the X23 encoder interface. 7. Remove the SIMOTION module from the power module or from the mounting panel, depending on the type of assembly (see the "Installation" chapter in the SIMOTION Manual). How to install the new SIMOTION module: Note Observe the information in the SIMOTION Manual, when installing, wiring and connecting the SIMOTION module. 1. Mount the new SIMOTION onto the power module, or onto the mounting panel (see the "Installation" chapter in the SIMOTION Manual). 2. Connect all previously removed connectors. 3. Terminate the load voltage supply cables at the terminal block. 4. Rewire the shielding of all cables. 5. Insert the original CompactFlash Card into the card slot of the new SIMOTION. 6. Restart the power supply. The new SIMOTION is immediately ready for operation. Commissioning Manual, 05/

144 Maintenance and service 5.2 Replacing modules (spare part scenario) Replacing SIMOTION modules without PC/programming device To enable a module replacement without a programming device/pc, you must back up the current non-volatile data to the CompactFlash Card. The user program can use the "_savepersistentmemorydata" system function to save the contents of non-volatile data to the CompactFlash Card. This ensures that the retain variables and the absolute encoder position are backed up to the CompactFlash 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 by using IT DIAG; for details, refer to the section titled Diagnostic data and nonvolatile data (Page 172). Note Non-volatile data that are not backed up to the CompactFlash 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 have been restored. In this case, homing (absolute encoder adjustment) must be repeated. See also User memory concept (Page 31) Replacing DRIVE-CLiQ components Module replacement DRIVE-CLiQ components can be replaced or newly inserted during operation (without POWER OFF) or when the system is switched off. Prerequisite The affected components are located at the end of the line. Procedure for removing a component 1. Deactivate the affected component or drive object. 2. Remove the DRIVE-CLiQ connector. 3. Remove the supply voltage for the component and remove the component. 144 Commissioning Manual, 05/2009

145 Maintenance and service 5.2 Replacing modules (spare part scenario) Procedure for installing a component 1. Mount the component and reconnect the supply voltage. 2. Reconnect the DRIVE-CLiQ cable at the same location (port). The cable must be the same length as the old one. 3. Activate the affected component or drive object. WARNING In order to replace this component, the module must be in a de-energized state. 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 for each individual component at a later point in time, using p9907/p9908 or by right-clicking in the topology. All data on the electronic rating plate are compared as standard. When p9909 = 1, the serial number and the hardware version of the new replacement component are automatically transferred from the actual topology to the reference topology, and then saved in the non-volatile memory. When p9909 = 0, serial numbers and hardware versions are not automatically transferred. The setting p9901 = 1 enables the spare parts/components replacement without tool support to be carried out. The new serial number of the spare part is automatically transferred from the actual topology to the reference topology and saved in the non-volatile memory. In order for this to occur, the components that have been replaced must be of the same type and have the same order number, such as "6SL3055-0AA0-5BA0". 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 coded in these. 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 the DRIVE-CLiQ components (e.g. a cross-exchange) are not accepted for safety reasons and are generated by a fault. 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; or as an alternative, by right-clicking in the topology. NOTICE In this case, incorrect insertion of components is no longer monitored. Commissioning Manual, 05/

146 Maintenance and service 5.2 Replacing modules (spare part scenario) Automatic upgrading/downgrading (FW update) When starting up, the system automatically upgrades or downgrades all DRIVE-CLiQ components to the version of the component firmware on the CompactFlash Card. Components that cannot be downgraded to the component firmware version on the CompactFlash Card (for example, old firmware on the CompactFlash 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 During an automatic FW update, please take note of the messages and alarms in the SIMOTION SCOUT detail window. An FW update on the is signaled by the RDY LED flashing yellow, while on the DRIVE- CLiQ components (TM, SMC, etc.) it is signaled by the RDY LED flashing red/green. FW update running: RDY LED flashes slowly (0.5 Hz) FW update complete: RDY LED flashes quickly (2 Hz) Go offline once all the FW updates are complete, then switch the 24 V supply for the upgraded/downgraded initialization components off/on. The update function can be deactivated using CU parameter p7826 in the expert list. Additional references For additional information about this topic, consult the SINAMICS S120 Commissioning Manual. See also Firmware update using a CompactFlash Card (Page 158) 146 Commissioning Manual, 05/2009

147 Maintenance and service 5.2 Replacing modules (spare part scenario) Replacing the fan Prerequisite Replace the fan if a warning is output by the temperature monitoring function as a result of a fan defect. The SIMOTION fans switch on depending on the internal module temperature. If the temperature reaches impermissible values, this is signaled by a warning at the drive end: A1009: CU warning: Control Unit overtemperature In this case, the temperature (CU parameter r0037[0]) of the SIMOTION has exceeded the specified limit value. Remedy: Check the supply air for the SIMOTION. Does the control cabinet temperature fall within the permitted range? Is natural convection possible? Check the fan for the SIMOTION. Is the fan failing to rotate, despite the warning? Is the fan blocked by dirt/foreign bodies? The warning will automatically disappear as soon as the limit value is undershot. If the fan is defective, it must be replaced. The fan can be ordered as spare part, see "Spare parts and accessories" in the SIMOTION Manual. CAUTION The fan of the SIMOTION module may only be replaced by qualified technical personnel and strictly in accordance with ESD guidelines! The module must be in a de-energized state. Use a flat-bladed screwdriver with an extremely thin blade; be careful not to damage the plastic enclosure. Observe ESD guidelines (refer to the section titled ESD guidelines (Page 189)). Avoid making contact with the printed circuit board. Commissioning Manual, 05/

148 Maintenance and service 5.2 Replacing modules (spare part scenario) Replacing the fan How to replace the fan: 1. Remove all connectors at the front of the modules (X120, X121, X124). 2. Use a flat-bladed screwdriver to release all 7 snap hooks on the plastic enclosure for the SIMOTION (3 on the left, 3 on the right, one at the bottom). Figure 5-1 Releasing the snap hooks (example) 3. Remove the plastic enclosure. The fan is located underneath the module. 4. Release the fan connector at the bottom left-hand side. To do this, press the release and the connector together gently and remove the connector. 1 Release the fan connector. 2 Remove the fan using the plastic lug. Figure 5-2, open 1. Carefully remove the fan from the middle plastic lug. 2. Insert the new fan and reattach the connector. 148 Commissioning Manual, 05/2009

149 Maintenance and service 5.2 Replacing modules (spare part scenario) 3. Check the position of the fan cables to ensure that they do not become jammed when the plastic enclosure is replaced. 4. Replace the plastic enclosure and re-engage all 7 snap hooks Replacing the CompactFlash card If spare parts are being used, you must seek the assistance of the Technical Support Center in order to convert the license key code of the defective CompactFlash Card to that of the new CompactFlash Card. Proceed as follows to write your project to the new CompactFlash Card: Change the CompactFlash card; for information, refer to the section titled Replacing the CompactFlash Card (Page 165). Write to the CompactFlash card; for information, refer to the section titled Writing to a CompactFlash card (Page 166). Detailed information on the subject of licensing can be found in the SIMOTION SCOUT Configuration Manual. Commissioning Manual, 05/

150 Maintenance and service 5.3 Adapting a project (new device type/device version) 5.3 Adapting a project (new device type/device version) Overview The project needs to be adapted if you want to replace the type (e.g. DP with PN) or version of the SIMOTION device in your existing project. Carry out this replacement in HW Config. A SIMOTION D can only be replaced with another if the SINAMICS version involved is the same or higher. It is not possible to downgrade to a lower SINAMICS version. When upgrading your user project, you must follow the steps outlined below depending on the type of upgrade you are carrying out: 1. Replace the SIMOTION device in HW Config; for information, refer to the section titled Replacing the SIMOTION device in HW Config (Page 151). 2. Upgrade the device version of SINAMICS components; for information, refer to the section titled Upgrading the device version of SINAMICS components (Page 153). 3. Upgrade the technology packages; for information, refer to the section titled Upgrading technology packages (Page 154). 4. Upgrade the libraries; for information, refer to the section titled Upgrade the libraries (Page 155). 5. Back up variables; for information, refer to the section titled Backing up variables (Page 155). 6. Back up the CompactFlash Card bootloader; for information, refer to the section titled Upgrading the CompactFlash Card's bootloader (Page 156). 7. Download the project to the target system; for information, refer to the section titled Downloading the project to the target system (Page 156). 150 Commissioning Manual, 05/2009

151 Maintenance and service 5.3 Adapting a project (new device type/device version) Replacing the SIMOTION device 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. Replacing a module requires the new module to be moved to the header of the module rack shown rather than to slot 2. Please note that you must not delete the 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". Commissioning Manual, 05/

152 Maintenance and service 5.3 Adapting a project (new device type/device version) 3. Move the new module to the top field of the module rack using drag-and-drop. Figure 5-3 HW Config module replacement 4. Confirm the dialog box that appears with "Yes" if you want 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 The data for the SIMOTION device is immediately accepted into the SIMOTION SCOUT project, and the entire project is saved. In this way, the project also accepts all changes in the project (e.g. axis configuration). If you are using technology packages in your project, these will also need to be updated. If the module hardware changes (e.g. the DP is replaced with the PN), proceed as described in the section titled Removing and replacing the SIMOTION (Page 143). 152 Commissioning Manual, 05/2009

153 Maintenance and service 5.3 Adapting a project (new device type/device version) Upgrading the device version of SINAMICS components Prerequisite You can upgrade the device versions of the configured SINAMICS devices (SINAMICS Integrated or CU3xx) using SIMOTION SCOUT. An upgrade is required for the SINAMICS Integrated in, for example, the following cases: The module type has been changed (e.g. from DP to PN) A module version has been changed (e.g. from DP V4.1 auf DP Vx.y) Note The SINAMICS version can only ever be upgraded in a project; it cannot be downgraded. Each SINAMICS Integrated must be upgraded separately. As an alternative to the procedure described below, the device versions of all configured SINAMICS devices (SINAMICS Integrated only; not CU3xx) can also be automatically upgraded using a "technology packages upgrade". This is particularly suitable for upgrading projects to another version, as the technology packages generally also need to be upgraded in such cases (for details, refer to the section titled Upgrading technology packages (Page 154)). Procedure 1. Right-click the respective device, e.g. the "SINAMICS_Integrated". 2. Select "Target Device" > "Device Version" from the context menu. The "Device Version..." dialog appears with all the available device versions listed. Figure 5-4 Device version 3. Select the SINAMICS Integrated device version you are using and click "Change version". This upgrades the SINAMICS components. If the module hardware changes (e.g. DP to PN), proceed as described under Removing and replacing the SIMOTION (Page 143). Commissioning Manual, 05/

154 Maintenance and service 5.3 Adapting a project (new device type/device version) Upgrading technology packages Upgrading technology packages When modules are replaced or project data is imported, the versions of the technology packages (TP) assigned to the individual technology objects (TO) are not automatically upgraded to a version valid for the SIMOTION device. This upgrade requires a separate step. To adapt the technology package version of the new SIMOTION device: 1. Select the desired SIMOTION device in the Project Navigator. 2. Choose "Select Technology Packages" from the context menu. The "Select Technology Packages" window opens. Note If the last step you performed was to replace the SIMOTION device, the "Technology Packages from Another Version" dialog box appears. Confirm this with "OK" to delete the existing links to the technology packages, thus enabling new technology packages to be assigned. The "Select Technology Packages" dialog box will now appear. 3. If technology objects for your project indicating an incorrect version appear under "Incorrect version", click "Update". Otherwise, continue with step 5. Note The device versions of all configured SINAMICS devices (SINAMICS Integrated only; not CU3xx) can also be automatically upgraded using the "Update" button. 4. The "Update Technology Packages" dialog box opens. Confirm with "OK". A message appears. 5. Confirm the message with "OK". 6. If the update is successful, a message appears. Confirm with "OK". 7. Click "OK" to confirm the "Select Technology Packages" dialog. The TP upgrade is completed. 154 Commissioning Manual, 05/2009

155 Maintenance and service 5.3 Adapting a project (new device type/device version) Upgrade the libraries An upgrade of the libraries you are using is required if the version of the SIMOTION device or TOs in your existing project has changed. 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 box with "OK". Note Please also observe the notes on device-dependencies in the SIMOTION SCOUT online help Backing up variables With the SCOUT functions "Back up variables" and "Restore variables", you have the option of backing up and restoring data that were 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: Remanent global device variables and unit variables, as well as TO retain data (V4.1 and higher) that are located in the FRAM of the control Data saved with _saveunitdataset or _exportunitdataset, and which are located on the CompactFlash Card Note When performing an upgrade with a firmware version that is 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) remain 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 A SIMOTION service selector switch, or IT DIAG. For information on this, refer to the section titled Diagnostic data and non-volatile data (Page 172). Commissioning Manual, 05/

156 Maintenance and service 5.3 Adapting a project (new device type/device version) Additional references For additional information, refer to the SIMOTION SCOUT Configuration Manual Upgrading the CompactFlash Card's bootloader Upgrading the may also make it necessary to upgrade the bootloader of the CompactFlash card. Detailed information on the CompactFlash Card, bootloader version, SIMOTION hardware, and SIMOTION firmware version compatibility relationships can be found in the software compatibility list. This list is available both in the documentation supplied on the SIMOTION SCOUT DVD (at \1_Important\German\Kompatibilität\).. and on the Internet at Internet address ( See also Bootloader on the CompactFlash card (Page 167) Downloading the 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. Prerequisite The firmware required is located on the CompactFlash Card; for information, refer to the section titled Firmware update using a CompactFlash Card (Page 158). Procedure 1. Save and compile the project. 2. Click "Connect with target system" to go online to the target system. 3. Execute the "Download to target system" command, and then select "Copy RAM to ROM" to download the updated project to the CompactFlash Card as well. 4. For the automatic subsequent configuring in the SINAMICS Integrated drive, you must now perform "Download to programming device". 5. Save the project. 156 Commissioning Manual, 05/2009

157 Maintenance and service 5.4 Performing a firmware and project update 5.4 Performing a firmware and project update Overview Upgrading SIMOTION The actions described in this section also apply to downgrading to an older version. Various options are available for performing a firmware and project update on the SIMOTION. For information on performing a firmware update using a CompactFlash Card, refer to the section titled Firmware update using a CompactFlash Card (Page 158). For information on performing a firmware and project update using IT DIAG, refer to the section titled Firmware and project update using IT DIAG (Page 162). For information on performing a firmware and project update using the device update tool, refer to the section titled Firmware and project update using the device update tool (Page 163). The SIMOTION only supports upgrading using the IT DIAG or device update tool with version V4.1 SP2 and higher. 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 updates. Prerequisite (firmware updates) You can find the latest firmware for SIMOTION D On the SIMOTION SCOUT DVDs (e.g. at...\3_d4xx\firmware\v4.1.1\d4xx.zip). On the Internet at Internet address ( Upgrading the SIMOTION automatically updates the firmware of all connected SINAMICS components. Note Observe the readme files and upgrade instructions included in the delivery of new SIMOTION versions. Use only CompactFlash Cards that have been approved for use with the SIMOTION and whose bootloader version is correct. You can find the compatibility relationships in the SIMOTION SCOUT Add-Ons "software products" compatibility list, as well as at Internet address ( Commissioning Manual, 05/

158 Maintenance and service 5.4 Performing a firmware and project update NOTICE The upgrade operation deletes all project data and parameters from the CompactFlash Card! Prerequisite (project updates) You have updated your project and, if necessary, adapted the device type and device version. For details, refer to the section titled Adapting a project (new device type/device version) (Page 150) Firmware update using a CompactFlash Card Procedure The following procedure describes how to perform the upgrade: 1. Switch off the power supply to the. 2. Remove the CompactFlash Card from SIMOTION and insert it into the CompactFlash Card adaptor of your PC. 3. Open Windows Explorer. The CompactFlash Card must be visible as removable data volume Windows Explorer under an arbitrary drive letter. 4. If necessary, back up the licenses, retain data, and user data on the CompactFlash Card to your PC (see the section below titled "Backing up licenses, retain data, and user data"). 5. Delete all the data from the CompactFlash Card. 6. Unzip the firmware file to the CompactFlash Card using a ZIP file utility such as WinZip. Always maintain the file structure when setting up the unpacking tool. 7. Copy the data saved in step 4 back to the appropriate folder structure on the CompactFlash Card. 8. Remove the CompactFlash Card from the CompactFlash Card adaptor of your programming device / PC. 9. Insert the CF card into the. 10. Switch on power to the. The new firmware is loaded from the CompactFlash Card to the SIMOTION module. 158 Commissioning Manual, 05/2009

159 Maintenance and service 5.4 Performing a firmware and project update Backing up licenses, retain data, and user data Prior to upgrading/downgrading firmware, as a precaution we would generally recommend backing up the entire contents of the CompactFlash Card to the PC/programming device using the card adapter and Windows Explorer. How you should proceed when it comes to backing up and subsequently restoring data on the CompactFlash Card depends on whether licenses and/or other retain data and user data required are located on the CompactFlash Card. If the CompactFlash Card contains no licenses and no other retain data or user data required You do not need to take any steps in this case. Delete the contents of the CompactFlash Card and upgrade the firmware as described. If the CompactFlash Card contains licenses (e.g. axis licenses) Before upgrading the new firmware, back up the "KEYS" directory to your PC. This can then be copied back to the CompactFlash Card once you have installed the new firmware. Note The license key is stored in the "KEYS" directory on the CompactFlash Card. When the SIMOTION device starts up for the first time (firmware version V4.1 or higher), the license key is saved in the boot sector of the CompactFlash 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 CompactFlash Card or rewriting the bootloader. If the Keys.txt file is no longer present on the CompactFlash 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. If you should lose the license key, you can access it again via the Web License Manager on the Internet, at Internet address ( You require the HW serial number printed on the CompactFlash Card to do this. In the Web License Manager, you have the option of displaying the corresponding license key. If the CompactFlash Card contains other required retain data/user data If you are using your application to back up data to the CompactFlash Card, you must back them up before upgrading the new firmware. Example: Backing up retain data (non-volatile data saved using _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 Commissioning Manual, 05/

160 Maintenance and service 5.4 Performing a firmware and project update 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 CompactFlash 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 that is 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) remain valid even after a version upgrade. Re-compiling and downloading project data in SIMOTION SCOUT Re-compile and download the project data after upgrading the. To do this, you have the following options: Download the project to the CompactFlash Card using the SIMOTION You require an online connection between the programming device/pc and SIMOTION for this purpose. Select the "Download project to target system" command to download the project to SIMOTION. The connection to the SINAMICS Integrated is automatically established. For details, refer to the section titled Downloading a project created offline to the target system (Page 70). Download the project directly to the CompactFlash Card using the CompactFlash Card adapter You can use a card reader to write the entire project to the CompactFlash Card, even while offline. In SIMOTION SCOUT, you can call the "Download to the file system" function in the context menu of the SIMOTION device. For details, refer to the section titled Loading a project created offline to the CompactFlash Card (Page 71). In both cases, the firmware update is performed automatically. 160 Commissioning Manual, 05/2009

161 Maintenance and service 5.4 Performing a firmware and project update Updating 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 CompactFlash Card. Components that cannot be downgraded to the component firmware version on the CompactFlash Card (for example, old firmware on the CompactFlash 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 automatically updated, depending on the FW version on the SINAMICS components and on the CompactFlash Card. During an FW update, please take note of the messages and alarms in the SIMOTION SCOUT detail window. An FW update on the SIMOTION is signaled by the RDY LED flashing yellow, while on the DRIVE- CLiQ components (TM, SMC, etc.) it is signaled by the RDY LED flashing red/green. FW update running: RDY LED flashes slowly (0.5 Hz) FW update complete: RDY LED flashes quickly (2 Hz) Go offline once all the FW updates are complete, then switch the 24 V supply for the upgraded initialization components off/on. Updating 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 p7826 = 1: Upgrade and downgrade p7826 = 2: Upgrade only CAUTION The automatic FW update via p7826 = 1 (upgrade and downgrade) must not be deactivated when Safety Integrated is used. If you are upgrading the firmware manually, proceed as follows: 1. Select the SINAMICS component in the Project Navigator, for example, SINAMICS Integrated. 2. Double-click "Configuration" in the project navigator. The "SINAMICS_Integrated - Configuration" dialog box will open 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 update. The list displays the current firmware version of the devices. Commissioning Manual, 05/

162 Maintenance and service 5.4 Performing a firmware and project update 5. Click "Firmware update" to download the new firmware to the devices. To do so, you must select all components whose firmware is to be updated. 6. When the firmware update is complete, switch the 24 V power supply off and on again. The device is now ready for operation. Note The SINAMICS components must be configured for a firmware update to take place. The firmware cannot be updated if the components are not programmed. You can also update the firmware by means of the Expert list. Refer to the SINAMICS S120 Commissioning Manual for a description of this procedure. See also Adapting a project (new device type/device version) (Page 150) Firmware and project update using IT DIAG The SIMOTION features an integrated web server that is licensed via the software option "SIMOTION IT DIAG". In addition to customized websites and comprehensive device/diagnostic information, one of the options that IT DIAG offers is performing firmware and project updates using a standard PC with Internet Explorer. Note An Ethernet or PROFINET interface is required for IT DIAG. For this reason, IT DIAG is only available on the SIMOTION PN, not the DP. For detailed information, refer to the SIMOTION IT Ethernet-Based HMI and Diagnostic Functions Diagnostics Manual. 162 Commissioning Manual, 05/2009

163 Maintenance and service 5.4 Performing a firmware and project update Firmware and project update using the device update tool Overview With SIMOTION V4.1 SP2 and higher, SIMOTION D Control Units and projects can be upgraded using upgrade data that was created at an earlier point in time. 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 or post to the machine operator. There is no need to use license keys, as licenses are retained. Retain data and unit data are retained when upgrades are performed, even across versions. An upgrade which has been imported can be discarded again, and a downgrade to the previous configuration performed. You can upgrade either a single SIMOTION device or multiple devices from one or more SIMOTION projects. It is possible to upgrade only parts of a configuration (e.g. Technology Packages only, firmware only, project only, etc.). Upgrade data are 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 them to a storage or upgrade medium: CompactFlash Card USB memory stick (D4x5 only; not with ) 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). Commissioning Manual, 05/

164 Maintenance and service 5.4 Performing a firmware and project update Upgrading with a CompactFlash Card 1. Switch the SIMOTION to be upgraded off. 2. Insert the CompactFlash Card into the SIMOTION. 3. Switch the SIMOTION back on. The will begin to process the upgrade data. The RDY LED will flash green during this process. Once the upgrade process is complete, the RDY LED will change To green (constant) if the process was successful To red (constant) if the process was not successful 4. Switch the off and on again to perform a restart. Downgrading If the upgrade was not successful (the machine is not behaving as required, for example), it is possible to undo the upgrade. To do this, proceed as follows: 1. Switch off the SIMOTION. 2. Set the service selector switch (switch 6) to ON. Figure 5-5 Switch position for downgrading 3. Switch the SIMOTION back on. The system restores the data that were backed up during the upgrade process (TP, project, user data). The data from the upgrade process are deleted. The SIMOTION device restarts once this is complete. Following startup, the configuration from the state present prior to the upgrade becomes active. 4. Set the service selector switch (switch 6) to OFF. Additional references Detailed information on upgrading devices can be found in the Upgrading SIMOTION Devices Operating Instructions. 164 Commissioning Manual, 05/2009

165 Maintenance and service 5.5 SIMOTION CompactFlash Card 5.5 SIMOTION CompactFlash Card Replacing the CompactFlash Card Prerequisite Note Always power down the unit before you insert or remove the CompactFlash Card! The SIMOTION is in a de-energized state when all the LEDs are OFF. Procedure How to replace the CompactFlash Card: 1. Shut down the power supply. 2. Remove the CompactFlash Card from the plug-in slot on the SIMOTION. To do this, grasp the gripping cavity between your thumb and forefinger and pull the card out. 3. Insert the new CompactFlash Card into the card slot. Push it in all the way with slight pressure until it engages. The insertion direction of the CompactFlash Card is identified by an arrow on the card and a matching arrow on the slot. The properly inserted card does not protrude from the SIMOTION housing. 4. Restart the power supply. Commissioning Manual, 05/

166 Maintenance and service 5.5 SIMOTION CompactFlash Card Writing to a CompactFlash card Overview You have the following options of writing data to a CompactFlash Card: Writing to a CompactFlash Card that is inserted in a SIMOTION D The programming device / PC must be online to SIMOTION in order to execute this function. Writing to a CompactFlash Card without a SIMOTION D module This function requires a CompactFlash Card adapter. Note CompactFlash Card are always shipped in formatted state. It contains the SIMOTION Kernel (D4xx firmware). Trouble-free operation of the CompactFlash Card can only be guaranteed if you do not modify its partitioning. Writing to a CompactFlash Card that is inserted in the SIMOTION D The CompactFlash Card can be used as storage volume for technology and user data (programs, configuration data and parameters) from the "volatile data" area. Proceed as follows: 1. Go online to SIMOTION on your programming device / PC (see the chapter "Creating a project"). 2. Select the "Copy RAM to ROM" command in SIMOTION SCOUT to write the data to your CompactFlash Card. Writing to a CompactFlash Card without a SIMOTION D module A CompactFlash Card adapter must be installed on the programming device / PC and can be used to write data to the CompactFlash Card. Always save your project data to CompactFlash Card using the programming device / PC before you update the SIMOTION firmware, for example. Note Do not use any of the onboard tools in Windows to modify or delete files which were written to the CompactFlash Card using the "Copy RAM to ROM" function in SIMOTION SCOUT. Such actions may irrevocably destroy your project. 166 Commissioning Manual, 05/2009

167 Maintenance and service 5.5 SIMOTION CompactFlash Card Formatting the CompactFlash Card You can format a faulty CompactFlash Card, for example. Proceed as follows: 1. Insert the CompactFlash Card into a CompactFlash Card adapter which is connected to your programming device / PC. 2. Format the CompactFlash Card in Windows (FAT or FAT16 file system). The CompactFlash Card is formatted. 3. If the CompactFlash Card bootloader is also defective, you will have to rewrite it. NOTICE The CompactFlash 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 167) Bootloader on the CompactFlash card Writing a bootloader A bootloader may need to be written in the following situations: When a new bootloader is required for the SIMOTION firmware version being used. When a new bootloader is required for the used SIMOTION hardware version. When the bootloader is defective. The bootloader version can be fetched using SIMOTION SCOUT device diagnostics. If this is not possible because of the following reason, this can be caused by an incorrect bootloader version. A potential fault description could be as follows: The SIMOTION does not power up, the RDY LED flashes red at 0.5 Hz and the RUN/STOP LED lights up red, or all the LEDs remain off. In this case, replace the bootloader version with the current version. Use the "Options > Write boot sector..." function to write the bootloader version in SIMOTION SCOUT to the CompactFlash Card. Note You require programming device/pc administrator rights in order to write to the boot sector. If you do not have administrator rights on your programming device/pc, an administrator can enter an administrator login for you in order to use this function, under "Options" > "Settings" > "Rights". Detailed information on the CompactFlash Card, bootloader version, SIMOTION hardware, and SIMOTION firmware version compatibility relationships can be found in the software compatibility list. This list is available both in the documentation supplied on the SIMOTION SCOUT DVD (at \1_Important\German\Kompatibilität\).. and on the Internet at Internet address ( Commissioning Manual, 05/

168 Maintenance and service 5.5 SIMOTION CompactFlash Card Recommended method of handling CompactFlash Cards Handling CompactFlash Cards correctly The following points should be noted when handling the CompactFlash Card: The CompactFlash Card may only be inserted or removed when the system is in a deenergized state. CompactFlash Cards cannot be rewritten as many times as the user wishes. With this in mind, it is better if you avoid writing user data from the application to the CompactFlash Card on a cyclical basis. Depending on the system, a writing process from the application may trigger one or more writing processes on the CompactFlash 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. We recommend you avoid switching off the module during write accesses to the CompactFlash Card (e.g. "Copy RAM to ROM", savepersistentmemorydata, _saveunitdataset, _exportunitdataset, etc.). 168 Commissioning Manual, 05/2009

169 Service and diagnostics Diagnostics by means of LED displays Overview The status LEDs display the operating modes or fault states of SIMOTION. Legend of the LED states Table 6-1 Legend of the LED states Symbol Meaning 1 LED on 0 LED off 0.5/1 LED flashes at 0.5 Hz: 2/1 LED flashes at 2 Hz: Λ LED flickers x The LED display is irrelevant to the states shown in the table LED displays The following table provides an overview of all relevant LED display combinations. Each LED can be lit in yellow, red, or green color. The color which corresponds with the LED signal state is also defined. Table 6-2 Diagnostics by means of LED display Meaning RDY RUN/STOP OUT > 5V SF/BF: SINAMICS Integrated ready for operation 1 x x x (green) SINAMICS Integrated in fault state Λ x x x (red) Startup of the without CF card or with CF card without valid 0.5/ operating system (the bootloader may be defective) (red) (red) Write access to CompactFlash Card 2/1 x x x (green) SIMOTION ready for operation x 1 (green or yellow) x x Commissioning Manual, 05/

170 Service and diagnostics 6.1 Diagnostics by means of LED displays Meaning RDY RUN/STOP OUT > 5V SF/BF: Fault event to which the user program (SIMOTION) cannot Λ Λ x Λ respond, or firmware error at the PROFINET interface. (red) (red) (red) The following actions may be required to rectify the fault: Power OFF/ON Check of the CompactFlash Card Re-commissioning Replacement of SIMOTION The following statuses are signaled: - A warning on the SINAMICS Integrated is pending. This status may occur if, for example, a DRIVE-CLiQ component is configured, but not present. - Module identification (recognition via LED) selected using SCOUT or p124. The RDY LED of the SIMOTION does not flash yellow/green as in the case of CUs, but instead lights up yellow constantly. 1 (yellow) x x x Ethernet LED (only for SIMOTION PN) DCP flashing of the module activated in the HW Config at Target system > Ethernet > Edit Ethernet node > "Search" button > "Flashing" button Priority: 0 1) Active interrupt which can be acknowledged (alarm, message, note) Priority: 1 1) Bus fault PROFIBUS master: At least one slave is missing PROFIBUS slave: No parameter assignment master found PROFINET: Failure of a connected I/O device; at least one of the assigned I/O devices cannot be addressed; faulty or missing configuration data. Priority: 2 1) Sublicensing of technology/option objects Priority: 3 1) Upgrade/downgrade operation running. 0.5/1 (yellow) The upgrade/downgrade operation has completed (power OFF/ON of the upgraded/downgraded devices is necessary) x x x 2/1 (green) x x x 1 (red) x x x 2/1 (red) x x x 0.5/1 (red) 2/1 (yellow) x x x x x x STOP to RUN transition x 2/1 (green) STOP/STOPU x 1 (yellow) RUN to STOP transition x 2/1 (yellow) Memory reset requested by SIMOTION, or by means of mode selector switch. x 0.5/1 (yellow) x x x x x x x x 170 Commissioning Manual, 05/2009

171 Service and diagnostics 6.1 Diagnostics by means of LED displays Meaning RDY RUN/STOP OUT > 5V SF/BF: Memory reset in progress x 0 x 0 Memory reset completed x 1 (yellow) x x Firmware download to the integrated PROFINET interface is busy 0 2/1 (yellow) Firmware download to the integrated PROFINET interface is completed SIMOTION cannot enter the RUN and Online mode 1 (green) 1 (yellow) x 2/1 (yellow) x Λ (red) 1) Priority of the displays: The displays always visualize the state which is assigned the numerically lowest priority level. The error of the next highest priority class is displayed after the cause of the previous signal state was eliminated. The LED "OUT > 5V" display is controlled only by the encoder evaluation for the integrated X23 encoder interface in SINAMICS Integrated. The table below lists the display states and their meaning. Table 6-3 LED display OUT > 5V Status Meaning 0 Electronic power supply is missing or outside the valid tolerance range. Power supply 5 V. Use of an encoder with 5 V power supply. 1 Electronics power supply for measuring system available. Power supply >5 V. (yellow) Caution: Always ensure that you can operate the encoder on the 24 V power supply (e.g. HTL encoder). Operation of a 5 V encoder on the 24 V encoder supply may lead to the destruction of its electronic components! This setting can be selected in the expert list of the drive in parameter p Note There are additional status indicators available for the SF/BF and RDY LEDs when upgrading/downgrading the SIMOTION using the device update tool. Additional references Detailed information can be found in the Upgrading SIMOTION Devices Operating Instructions. Commissioning Manual, 05/

172 Service and diagnostics 6.2 Diagnostic data and non-volatile data 6.2 Diagnostic data and non-volatile data Overview With V4.1 SP2 and higher, and without the need for the SCOUT engineering system, you can use simple operations (e.g. setting switches) Back up diagnostic data, including non-volatile data (retain data) to the CompactFlash Card. For details, refer to the section titled Backing up diagnostic data and non-volatile data (Page 173). Back up websites to the CompactFlash Card, including the most up-to-date content for diagnostic purposes, refer to the section titled Diagnostics via websites (Page 178). For information on restoring backed-up non-volatile data (retain data), refer to the section titled Restoring non-volatile data (Page 179). 172 Commissioning Manual, 05/2009

173 Service and diagnostics 6.2 Diagnostic data and non-volatile data Backing up diagnostic data and non-volatile data Diagnostic data Following a fault on a SIMOTION device, diagnostic data (e.g. diagnostic buffer content, upto-date content of websites, etc.) can provide important information on the cause of the fault. For this purpose, these data can be backed up to the CompactFlash Card using a simple operation (e.g. by setting a switch on the ). You then have the following options for the diagnostic data: Fetching them from the CompactFlash Card using a card reader Downloading them using IT DIAG or FTP You can also use them for diagnostic purposes or provide technical support with them for evaluation purposes. You have various options in terms of backing up the diagnostic data: Backing up during operation (in STOP/STOPU/RUN mode); for details, refer to the section titled Procedure for backing up during operation (Page 174) Using IT DIAG; IT DIAG also offers the option of fetching diagnostic data online. Using a service selector switch Backing up while the module is starting up; for details, refer to the section titled Procedure for backing up during startup (Page 175). Using a service selector switch Controlling diagnostic data creation using an INI file stored on the CompactFlash Card Note An Ethernet or PROFINET interface is required for IT DIAG. For this reason, IT DIAG is only available on the SIMOTION PN, not the DP 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. Commissioning Manual, 05/

174 Service and diagnostics 6.2 Diagnostic data and non-volatile data 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 websites and TO alarm information. Data are backed up: Using "Diagnostics > Diagnostics Files" in IT DIAG; for details, refer to the section titled Backing up diagnostic data and non-volatile data using IT DIAG (Page 181) Using a service selector switch (see description below) 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 the "Diagnostics" setting (i.e. set DIP switch S7 to ON). The positions of the mode selector switches are not relevant (i.e. the operating mode set remains unchanged). The diagnostic data and non-volatile data can be created in STOP, STOPU, and RUN modes. Figure 6-1 Writing diagnostic data using a switch position 2. The diagnostic data and non-volatile data are backed up to the CompactFlash Card. The backup process is indicated by the status LEDs as follows: Table 6-4 LED displays during backup process Status Backup in progress Backup complete LED displays on the RUN/STOP LED flashes yellow at 2 Hz RUN/STOP-LED flashes green at 2 Hz and SF LED lights up 1. Once the backup is complete, switch off the. 2. Remove the CompactFlash Card and reset the service selector switch to its original setting. 174 Commissioning Manual, 05/2009

175 Service and diagnostics 6.2 Diagnostic data and non-volatile data Procedure for backing up during startup Procedure Backing up diagnostic data and non-volatile data during startup provides you with diagnostic information without websites/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 are backed up Using a service selector switch or Using an INI file saved on the CompactFlash Card The procedure for each is described below. Service selector switch Data are backed up using a service selector switch as follows: 1. Set the service selector switch to "Diagnostics" (i.e. set DIP switch S7 to ON). The switch positions of the mode selector switches are not relevant (i.e. the operating mode set remains unchanged). Figure 6-2 Writing diagnostic data using a switch position 2. Switch the off and on again. 3. Wait for the device to start up. The diagnostic data and non-volatile data are backed up to the CompactFlash Card during startup, provided that this is still possible and is not prevented by HW defects,for example. 4. Once the backup is complete, switch off the. 5. Remove the CompactFlash Card and reset the service selector switch to its original setting. Commissioning Manual, 05/

176 Service and diagnostics 6.2 Diagnostic data and non-volatile data INI file in the main CompactFlash 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 CompactFlash Card directory. 4. Insert the CompactFlash Card into the module, which is switched off. 5. Switch the on and allow the SIMOTION device to start up. The diagnostic data and non-volatile data are backed up to the data carrier during startup, provided that this is still possible and is not prevented by HW defects, for example. 6. Once the backup is complete, switch off the SIMOTION device. 7. Remove the CompactFlash Card. NOTICE To suppress startup in diagnostics mode again, you must delete the simotion.ini file from the CompactFlash Card 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 commercially available 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 6-5 Diagnostic data on the CompactFlash Card File DIAGBUF.TXT PMEMORY.XML TOALARMS.TXT Application Diagnostic buffer in a simple text format: Numerical values; no specific plain text. A text editor is used for evaluation purposes. Non-volatile data (retain data) An operation can be used to restore the non-volatile data saved after a CPU has been replaced. (For details, refer to the section titled Restoring non-volatile data (Page 179).) 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). 176 Commissioning Manual, 05/2009

177 Service and diagnostics 6.2 Diagnostic data and non-volatile data File Website Other files Application If the diagnostic data are backed up, the URLs are requested from the text file (DIAGURLS.TXT) and stored as websites together with their contents. (For details, refer to the section titled Diagnostics via websites (Page 178).) Note: Note:The websites are only stored if diagnostic data are created during operation (STOP/STOPU/RUN). All other files stored in the directory are only of relevance to technical support. 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. Commissioning Manual, 05/

178 Service and diagnostics 6.2 Diagnostic data and non-volatile data 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 CompactFlash Card when diagnostic data are created during operation. (For example, "devinfo.mcs" must be entered for the "devinfo.htm" website.) Since the sites 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 sites, it is possible to store customized sites. Information on creating sites of this type can be found in, for example, Utilities & Applications. Figure 6-3 Diagnostic buffer at the point when diagnostic data was created The following points must be noted for the DIAGURLS.TXT file: A DIAGURLS.TXT file containing the standard IT DIAG sites is automatically created if you have not stored your own DIAGURLS.TXT file. Standard IT DIAG sites are entered "without" a path specification (e.g. "devinfo.mcs" for the standard IT DIAG site "devinfo.htm"). Customized IT DIAG sites (such as "user.htm") in the \USER\SIMOTION\HMI\FILES directory on the CompactFlash 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 1 file name may be used per line. 178 Commissioning Manual, 05/2009

179 Service and diagnostics 6.2 Diagnostic data and non-volatile data Empty lines are not permitted (an empty line will be interpreted as the end of the list). No distinction is made between upper-case and lower-case letters. It does not matter whether you use "\" or "/" in the path name. Figure 6-4 Depiction of DIAGURLS.TXT editor Restoring non-volatile data Prerequisite The diagnostic data and non-volatile data have been backed up to the CompactFlash Card. For details, refer to the section titled Backing up diagnostic data and non-volatile data (Page 173). Procedure To restore non-volatile data after a CPU has been replaced, proceed as follows: 1. Insert the CompactFlash Card into the new (which must be switched off). 2. Set the switch to the "Delete non-volatile data" setting (i.e. set DIP switch S5 to ON). The positions of the mode selector switches are not relevant (i.e. the operating mode set remains unchanged). Figure 6-5 Switch position for restoring non-volatile data Commissioning Manual, 05/

180 Service and diagnostics 6.2 Diagnostic data and non-volatile data 3. Allow the to start up; the non-volatile data will be restored while this is taking place. If there is a file called "PMEMORY.XML" in the "USER/SIMOTION" directory, 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 non-volatile data" switch position is selected, the non-volatile data of the is first deleted and then restored by means of the PMEMORY backup file. 4. Once the has started up, switch it off. 5. Reset the service selector switch to its original setting. 6. Switch the back on. 180 Commissioning Manual, 05/2009

181 Service and diagnostics 6.2 Diagnostic data and non-volatile data Backing up diagnostic data and non-volatile data using IT DIAG SIMOTION devices feature pre-configured, standard IT DIAG sites. These sites can be displayed via Ethernet using a commercially available browser. Additionally, you have the option of creating your own websites and incorporating service and diagnostic information. 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. 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 6-6 IT DIAG Table 6-6 Functions on the "Diagnostic files" website Button Create general diagnostic files Create html diagfiles Function 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. This button is used to save diagnostics websites on the data carrier. It should be noted that only those sites that are listed in the DIAGURLS.TXT file in directory...\user\simotion\hmi\syslog\diag are saved (for details, refer to the section titled Backing up diagnostic data and nonvolatile data (Page 173)). Commissioning Manual, 05/